Dover PSG Ebsray R Series Guide

Publication # 2403-15 EN
EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
R SERIES
MODEL RX33
…. For Submersible
LPG APPLICATIONS

2
CONTENTS
SECTION 1 –GENERAL.............................................................................................................................................. 4
1.1 INTRODUCTION................................................................................................................................... 4
1.2 TRANSPORTATION AND PACKING.................................................................................................... 4
1.3 RECEIVING INSPECTION.................................................................................................................... 4
1.4 HANDLING............................................................................................................................................ 4
1.5 WARRANTY.......................................................................................................................................... 4
SECTION 2 –SYSTEM DESCRIPTION....................................................................................................................... 5
2.1 EBSRAY RX33 SUBMERSIBLE LPG PUMPING SYSTEM.................................................................. 5
2.2 “THREE-TIER” PROTECTION SYSTEM .............................................................................................. 5
2.3 DPS (DIFFERENTIAL PRESSURE SWITCH) ...................................................................................... 5
2.4 BYPASS VALVE ................................................................................................................................... 5
2.5 PPVVALVE (POSITIVE PRESSURE VENTILATION VALVE) ............................................................ 5
2.6 PUMP CONTROLLER........................................................................................................................... 5
SECTION 3 –INSTALLATION..................................................................................................................................... 6
3.1 PRE INSTALLATION ............................................................................................................................ 6
3.2 INITIAL INSTALLATION........................................................................................................................ 6
3.2.1 Location......................................................................................................................................... 6
3.2.2 Pumpset Installation...................................................................................................................... 6
3.2.3 Port Alignment............................................................................................................................... 6
3.2.4 Discharge Riser............................................................................................................................. 7
3.2.5 Electrical Conduit .......................................................................................................................... 7
3.2.6 Pumpset & System Piping Connections........................................................................................ 7
3.2.7 Recommended Order of Assembly................................................................................................ 8
3.2.8 Discharge Pipe Fittings.................................................................................................................. 9
3.2.9 DPS (Differential Pressure Switch)................................................................................................ 9
3.2.10 Bypass Valve................................................................................................................................. 9
3.2.11 PPVVALVE (Positive Pressure Ventilation Valve)....................................................................... 9
3.2.12 Leak Check ................................................................................................................................. 10
3.3 ELECTRICAL CONNECTIONS –PUMPSET AND SYSTEM ............................................................. 10
3.3.1 Junction Box................................................................................................................................ 11
3.3.2 DPS (Differential Pressure Switch).............................................................................................. 11
3.3.3 Connecting Cable........................................................................................................................ 11
3.3.4 Pump Controller .......................................................................................................................... 11
SECTION 4 –OPERATION........................................................................................................................................ 11
4.1 DESCRIPTION.................................................................................................................................... 11
4.2 LUBRICATION.................................................................................................................................... 11
4.3 PRE-STARTUP CHECKLIST.............................................................................................................. 11
4.4 STARTUP PROCEDURE.................................................................................................................... 12
SECTION 5 –PUMP CONTROLLER......................................................................................................................... 13
5.1 DESCRIPTION OF PUMP CONTROLLER ......................................................................................... 14
5.2 ACTIONS ............................................................................................................................................ 14
5.2.1 Initial Settings.............................................................................................................................. 14
5.2.2 To Set Date & Time..................................................................................................................... 14
5.2.3 To Set DPS Time (Max 45s)........................................................................................................ 14
5.2.4 To View Settings & Set ‘Run-On’ Time (Valid Options 0 or 2mins) ............................................. 14
5.2.5 View Logs.................................................................................................................................... 14
5.2.6 To Reset a Critical Fault.............................................................................................................. 14
5.3 NORMAL OPERATION....................................................................................................................... 14
5.3.1 ‘RUN’ ........................................................................................................................................... 14
5.3.2 DPS Bypass Timer...................................................................................................................... 14
5.3.3 ‘Run-On’ Time ............................................................................................................................. 15
5.3.4 ‘TEST’.......................................................................................................................................... 15
5.3.5 Normal Operation PLC Displays.................................................................................................. 15
5.4 PUMPSET/PUMPING SYSTEM FAULT DETECTION & PROTECTION FUNCTIONS...................... 15
5.4.1 Critical Faults............................................................................................................................... 15
5.4.2 Preventative Faults...................................................................................................................... 16
5.4.3 Informative Faults........................................................................................................................ 16
5.5 PUMPSET/PUMPING SYSTEM diagnostics....................................................................................... 16
SECTION 6 –MAINTENANCE................................................................................................................................... 17
6.1 INSPECTION ...................................................................................................................................... 17
6.2 SERVICE............................................................................................................................................. 17
6.3 SERVICE EXCHANGE........................................................................................................................ 17
6.4 SPARE PARTS ................................................................................................................................... 17
SECTION 7 –TROUBLESHOOTING......................................................................................................................... 18
APPENDIX A –TYPICAL INSTALLATION P&ID ...................................................................................................... 23
APPENDIX B –SUBMERSIBLE PUMPSET –OUTLINE DIMENSIONS AND SPECIFICATIONS........................... 24
APPENDIX C –TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAM................................................... 25
APPENDIX D –SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST............................................................. 26
APPENDIX E –EBSRAY PUMPSET RUN LOG........................................................................................................ 27
APPENDIX F –CERTIFICATIONS & DECLARATIONS OF CONFORMITY............................................................. 28

3
IMPORTANT NOTES
1. 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 RX33 Submersible
Pumpset and the Pumping System in general.
2. Products with the mandatory European CE mark affixed indicate conformity to the essential health and safety
requirements via their applicable EU Directives (e.g. ATEX 94/09/EC, Machinery 98/37/EC etc).
As certain specific products/equipment outlined in this Publication are CE marked (meaning the equipment has
been assessed and supplied in conformity to those Directives), STRICT ADHERENCE with ALL the
instructions and recommendations forms an essential part in maintaining the product/equipment’s conformity.
Failure to comply with the instructions and recommendations contained in this Publication may void
CE conformity.
3. This Publication does NOT depict:
a) Ancillary required equipment related to the fabrication, installation and operation of the Pumpset e.g.
miscellaneous flanges, fittings etc.
b) Required equipment unrelated to the Pumpset e.g. tank fill lines, vapour return lines, emergency shutdown
systems etc.
c) The materials and method of fabrication and/or installation of the tank and required sub-systems.
4. It is the responsibility of the designer, fabricator and the installer of each actual tank and required sub-systems to
ensure that:
a) The EBSRAY specifications within this Publication and any other relevant EBSRAY documents are STRICTLY
adhered to.
b) Any variation (including use of equipment deemed "Equivalent") or addition to the EBSRAY Specifications, as
related to the Pumpset and Pumping System in general, meet EBSRAY's minimum requirements.
c) All design, fabrication and installation of the tank and sub-systems is STRICTLY in accordance with all relevant
National, State and Local Codes, Regulations, Standards and Directives.
5. 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.
Terms used in this publication requiring special attention:
1.
Non-compliance with requirements under this heading could create circumstances which may lead to
serious personal injury or death or substantial property damage.
2.
Non-compliance with requirements under this heading could create circumstances which may lead to
personal injury and/or which may cause damage to the Pumpset and/or ancillary equipment.
3.
Items under this heading draw attention to legal and/or statutory requirements which control the
installation and use of this type of equipment. Non-compliance with these requirements may create a
dangerous situation and/or result in damage to the Pumpset and ancillary equipment.
4. NOTE:
Items under this heading are to draw attention to assembly procedures, techniques and methods of
operation etc. which are important to ensure correct installation and operation of equipment and which, if
not followed, may result in damage, failure or poor performance of Pumpset and ancillary equipment.
BCLand PPVare Registered Trademarks of Ebsray Pumps Pty. Ltd
ABBREVIATIONS:
AFL Automatic Fill Limiting Valve
BCLBearing Cooling and Lubrication
System
DPS Differential Pressure Switch
HBT High Bearing Temperature
MOL Motor Overload
PPVPositive Pressure Ventilation
EBS-RAY PUMPS Pty. Limited
628 Pittwater Road
Brookvale NSW 2100 Australia
Phone: [phone])
Fax: [phone])
www.ebsraypumps.com.au
or
Contact Ebsray Representative:
DANGER
WARNING
CAUTION
DANGER

4
SECTION 1 –GENERAL
1.1 INTRODUCTION
This publication is intended to assist those involved
with the installation, operation and maintenance of
EBSRAY Model RX33 Regenerative Turbine
Submersible Pumpset and the pumping system.
NOTE: These instructions are intended to assist
correct Pumpset installation, operation and
maintenance requirements. They are additional to,
and do not supersede or override any applicable
statutory, legal or regulatory requirements.
Before starting any work,
this Publication should be
completely read/reviewed
by all persons involved with the work. If any part of
this Publication is unclear, obtain clarification
before proceeding with any work.
As LPG (propane and
butane) is regarded as a
flammable liquid, extreme caution must be taken to
ensure total compliance with all necessary
statutory Codes, Regulations, Standards and
Directives. These requirements must be fully
understood and exercised in the installation,
operation and maintenance of EBSRAY RX33
Pumpsets.
Installation and servicing
of this equipment should
be performed by suitably qualified competent
personnel in accordance with relevant Codes,
Regulations, Standards, Directives and site
restrictions, in conjunction with these
instructions.
When the equipment supplied utilises components
other than those manufactured by EBSRAY e.g.
electrical equipment, switches, fittings, valves, etc
reference should be made to the original
manufacturer's data before installation or servicing is
commenced. Failure to observe these details may void
the Warranty.
The Pumpset must be
operated within the
original selected design parameters of flow,
pressure, temperature, voltage and current with
LPG of internationally accepted (ISO) quality and
specification only. Should any change be
contemplated, please confer with EBSRAY in order
to verify the suitability of such a change.
1.2 TRANSPORTATION AND PACKING
Standard domestic packing is suitable for shipment in
covered transports. Pumpset ports must be sealed to
exclude ingress of condensation, moisture or foreign
material. When received on site the Pumpset must be
stored in a dry covered area. Motor Leads must not be
damaged.
NOTE: If Pumpset is not installed and
commissioned immediately, special preservative
techniques will be required. (Refer to EBSRAY).
e.g. If the Pumpset is installed, but not
commissioned, low pressure nitrogen can be
used to purge and seal the Pump Housing to
protect Pumpset from the effects of condensation.
Never allow water or any
corrosive product to enter the Pumpset, Motor or
electrical conduit. This may damage the Pumpset
and will void the Warranty.
1.3 RECEIVING INSPECTION
SHORTAGES and/or DAMAGE: On receipt of
equipment, check all items against the dispatch
documents and inspect for damage. Any damage or
shortage incurred during transit should be noted on the
packing note and on both your own and the carrier's
copy of the consignment note. A claim should be made
immediately on the transport company. Also advise
EBSRAY or their Appointed Representative.
Should a shortage be evident on receipt, notify
EBSRAY immediately giving full details and packing
note number.
1.4 HANDLING
Do not drop Pumpset! Care should be taken in
moving/handling Pumpsets. A sling should be placed
under or around a Pumpset in order to minimise stress
on the internal components.
The Pumpset should be lifted in such a manner as to
ensure compliance with the relevant lifting codes.
Severe internal Pumpset damage may result if
correct handling and due
care is not taken.
No welding is to be performed on any part of the
system (discharge piping, vapour returns, conduits
etc.) with Pumpset/wires installed. Failure to
observe this warning could result in severe Motor
and/or wiring damage and will void the Warranty.
1.5 WARRANTY
1. All EBSRAY manufactured pumps and equipment
are warranted as standard for one (1) year against
faulty workmanship and/or materials. Refer to
EBSRAY PUMPS 'Standard Conditions of Sale
and Warranty' publication for details. RX33
Pumpset Extended Warranty conditions and
exceptions are as follows:
2. For new Pumpsets, a two (2) year or 7,500 hours
(whichever occurs first) Warranty applies on
RX33 Pumpsets:
a) when installed and operated in strict
accordance with the system design and
recommendations as set out in the current
EBSRAY IO&M manual supplied with each
Pumpset and
b) when fitted with an EBSRAY Pump Controller
or with an EBSRAY PLC.
3. For Service Exchange Pumpsets, a one (1) year
or 3,750 hours (whichever occurs first) Service
Exchange Warranty applies on RX33 Pumpsets -
all as per a) and b) above
4. RX33 Pumpset Warranty is voided if the Pumpset
is installed and operated:
a) without the EBSRAY Pump Controller
installed and connected, or
b) without the EBSRAY PLC installed and
connected, or
c) without EBSRAY’s written agreement of an
alternative method of Pumpset protection
CAUTION
DANGER
WARNING
ER
WARNING
ER
WARNING
ER
DANGER
DANGER

5
5. To validate Warranty conditions, a completed copy
of the RX33 Pumpset Run Log, Appendix E
MUST BE completed in full and returned to
EBSRAY for registration. Failure to do so may void
the Warranty.
Refer to EBSRAY or Appointed Representative for
clarification or further details on the RX33 New or
Service Exchange Pumpset Warranty conditions.
SECTION 2 –SYSTEM DESCRIPTION
2.1 EBSRAY RX33 SUBMERSIBLE LPG
PUMPING SYSTEM
The system is designed around the RX33 Submersible
Pumpset which is a single stage Regenerative Turbine
Pump, close coupled to a Submersible Electric Motor
(See Specifications APPENDIX B).
The combination of robust, specially designed, 'product
lubricated' bearings using EBSRAY's unique BCL
system and the EBSRAY "Three-Tier" Protection
System ensures reliable operation over the intended
periods between routine maintenance overhauls.
The EBSRAY RX33 is designed as a 'fully serviceable'
pumpset.
Figure 1
2.2 “THREE-TIER” PROTECTION SYSTEM
The EBSRAY "Three-Tier" Protection System forms an
integral part of the pumping system which ensures
proper pumpset performance. (Refer Warranty) The
basic functions of this system are as follows:
1. 'HBT' (High Bearing Temperature) Operation of the
system will be halted if fluid within the BCLSystem
exceeds a preset temperature.
2. 'DPS' (Differential Pressure Switch) Operation of the
system will be halted if Differential Pressure falls
below a preset level during operation or is not
developed above the minimum level within a preset
time after startup.
3. 'MOL' (Motor OverLoad) Operation of the system
will be halted if motor current exceeds a preset
maximum setting.
Following automatic pumpset shutdown from any of the
above three functions requires access to the Pump
Controller for reset. Reset is protected by an interlock
with the keyed ‘RUN-OFF-TEST’ switch. i.e. the fault
can be isolated for 'controlled' assessment and fault
rectification prior to reset and re-start.
2.3 DPS (DIFFERENTIAL PRESSURE SWITCH)
To ensure adequate (lubrication/cooling) flow through
the Pump/Motor internals, overall pumping system
differential pressure is monitored and kept above a
predetermined minimum level.
The DPS signals the Pump Controller if the minimum
system differential pressure:
a) Is not attained on startup after the preset time
delay.
b) Falls below the predetermined differential pressure
during pumping/operation of the Pumpset
2.4 BYPASS VALVE
The EBSRAY RV18-NRV Bypass Valve plays a pivotal
role in the overall LPG system. It controls the following
functions:
1. Maintains pump system differential pressure as
required for optimum flow rate into vehicles.
2. Enables the RX33 pumpset BCLSystem
pressure requirements to be met and maintained.
3. Forms an integral part of the overall "Three Tier"
protection system function.
4. Softseat 'backcheck' function helps to eliminate
LPG drain-back when pumpset is idle.
2.5 PPVVALVE (POSITIVE PRESSURE
VENTILATION VALVE)
The PPVValve's low opening/closing pressure allows
equalisation of liquid level in the pump housing when
the Pumpset is not operating. In addition it prevents
rapid dropping of the liquid level in the pump housing
during start up, thus enabling maximum utilisation of
the tank's capacity. Correct installation (vertically
mounted) is essential for proper functioning of the
PPVValve.
2.6 PUMP CONTROLLER
The L861002 series pump controller houses the PLC
and associated control circuits that monitors and
controls the operation of the Pumpset. Pumping
System information is displayed on an LCD screen.
NOTE: This publication is specific to the L861002
Series of Pump Controllers. Ebsray offers
alternative pump monitoring and control equipment
for various applications/markets. Refer to IOM
supplied with the alternative Ebsray pump
monitoring and control equipment as required.
Contact your Ebsray authorised representative for
details.

6
SECTION 3 –INSTALLATION
Installation and removal of this equipment should be performed by suitably qualified
competent personnel in accordance with relevant Codes, Regulations, Standards,
Directives and site restrictions - in conjunction with these instructions.
Never loosen or remove fittings, flanges, etc. while under pressure (vapour pressure of
LPG may be very high), always isolate components or pipework and depressurise
prior to work.
3.1 PRE INSTALLATION
The EBSRAY RX33 utilises a Connector Housing that
provides for either Coaxial or Parallel wiring
connections. Ensure that the supplied Pumpset has the
required configuration for your installation.
Reconfiguration of the wiring connection is possible by
authorised representatives of EBSRAY.
3.2 INITIAL INSTALLATION
3.2.1 Location
The pumpset is designed for installation in a
housing/chamber which is installed in, and thus forms
part of the pressure vessel. This housing is constructed
from 5” Sch 40 pipe or 125mm ID Tube. The bore and
end (inside bottom) of this housing must be clear of any
intrusions. Allow a clearance of at least 50mm from the
underside of the housing to the inside wall of the tank.
The opening in the tank turret cover must be concentric
with the housing. The housing must be perpendicular to
the tank turret cover.
The inlet port of the housing must be at least DN40. It
is isolated from the tank with a remotely operated
DN40 (full bore) ball valve and an excess flow valve (in
some countries) designed for pumpset inlet (suction)
duties. The centre height of the inlet port must be
42mm (min) above the bottom (inside) of the housing.
(Refer Appendix A –P&ID)
3.2.2 Pumpset Installation
Pumpset should hang vertically from the riser without
contacting the sides or bottom of the pump housing.
Two guide rings, one at each end of the pumpset,
assist in electrical isolation of the pumpset from the
housing walls should nominal contact occur. Ensure
that the pump housing is straight and free from
intrusions and/or debris. The discharge riser must be
concentric with, and perpendicular to, the pump
housing cover.
NOTE: Debris e.g. welding slag, pipe scale,
grinding swarf etc. left in the pump housing can be
drawn into the pump casing causing serious
damage and voiding the Warranty. Clean pump
housing TOTALLY prior to pumpset installation.
When installed, the riser flange must be totally
insulated from the turret cover by means of a cathodic
insulation gasket and insulated spacers at the
fastenings.
3.2.3 Port Alignment
Accurate alignment of the pumpset inlet port with
the pump housing port is critical for efficient
pumpset operation. Vertical and angular alignment
must be within ±5mm for the pump to operate to
maximum performance without cavitation.
When measuring and marking for port alignment, be
sure to allow for thickness of cathodic gasket.
Clearance of 5mm (min) is required between bottom of
pumpset and bottom (inside) of pump housing. Should
underside of pump touch housing, severe mechanical
damage will result and electrical insulation will be
negated.
NOTE: External position of inlet valve remote
handle does not necessarily determine port
alignment. Only rely upon actual measurements
taken from the inside of the pump housing.
The suggested method for ensuring correct angular
port alignment is to mark the edge of the pump housing
cover (flange) in a position which represents the
centreline of the pumpset inlet port. Also mark the top
of the turret cover in a position which represents the
centreline of the housing port. Using a stringline to
ensure alignment, screw discharge riser into pumpset.
Refer Figure 2. and Appendix B.
Figure 2
CAUTION
DANGER
DANGER

7
3.2.4 Discharge Riser
To determine dimension ‘A’ (Refer to Figure 3):
1. Determine (measure) depth of pump housing inlet
port centreline from top of turret cover (X).
2. Add thickness of isolation gasket (Y).
3. Subtract 855mm to allow for pumpset length (to
centre line of inlet port).
4. A=X+Y-855
The result is the length of the riser (discharge pipe)
from the end of the thread to the underside of the pump
housing cover (flange) (A).
The top of the riser (above flange) must be fitted with a
coaxial splitting arrangement which provides a 1" (F)
NPT thread for the conduit exit, concentric and parallel
with the riser pipe plus a discharge connection
Figure 3
3.2.5 Electrical Conduit
The following relates to Coaxial conduit connection as
shown in Figure 3. For Parallel conduit connection
(external to and parallel to the Discharge Riser) refer to
your local Ebsray representative.
To determine minimum overall length of conduit –‘C’
(Refer to Figure 3 and Table 1):
1. Determine height of discharge riser above
underside of flange (Z) (to top of 1" (F) NPT thread).
2. Add length of discharge riser pipe determined
previously (A).
3. Add 90 mm to allow for minimum conduit length
required for fittings.
4. C=Z+A+90
The result is the minimum overall conduit length
required (C).
Table 1
Top of Turret Cover to
Pumpset Inlet Port
Centreline
X=
(measured)
Gasket Thickness
Y =
RX33 Installation
allowance
-855
Riser Length in Housing
A = X+Y-855
Required Riser above
Gasket
Z=
(site requirement)
Discharge Riser Length
A+Z
Coaxial Conduit Length
(Min)
C= A+Z+90
3.2.6 Pumpset & System Piping Connections
Refer to Appendix A - P&ID for system arrangement
and relative positioning of components.
It is extremely important
that no piping stresses
be transferred to the pumpset.
Two connections to pumpset are required for
installation:
1. The discharge pipe (riser)
2. The electrical conduit
The discharge port has a 1-1/2" NPT female thread
and the conduit port has a 3/4" NPT female thread.
Both NPT threaded connections on pumpset require a
thread engagement as per ANSI/ASME B1.20.1-1983.
EBSRAY recommend at least 8 full turns for correct
installation and sealing.
The Tube Connectors for electrical conduit supplied by
and/or recommended by EBSRAY must be fitted and
secured in accordance with the manufacturer's
(Swagelok or equal) recommendations. Ensure correct
positioning prior to tightening. Once tightened, the axial
position of fittings on the conduit cannot be altered and
any changes will require replacement of conduit and
fittings. (27 mm x 29 mm AF tube spanner is required)
Prior to fitting any wiring
into conduits, all burrs
and sharp edges must be removed from conduit
ends.
Figure 4
NOTE: Conduit length should be accurately
determined prior to any installation. Cutting
conduit with wires installed is not recommended.
WARNING
ER
WARNING
ER

8
NO WELDING is to be
performed on any part of
the system (discharge piping, vapour returns or
conduits) with pumpset/wires installed. Failure to
observe this warning could result in severe motor
and/or wiring damage and void the warranty.
3.2.7 Recommended Order of Assembly
1. Support the pumpset in the horizontal position.
2. Fit straight 3/4" NPT compression tube fitting to the
conduit port of the pumpset with appropriate thread
sealant or tape. This fitting must be gas-tight.
3. Fit conduit over motor leads taking great care not to
damage the leads.
4. Fit conduit to compression tube fitting and tighten
nut on fitting as shown in Figures 5 & 7 (2.5 mm
hex key used as a no-go gauge which is
approximately 1¾ turns after hand tight.) This
connection must be gas-tight.
5. Fit Cathodic Insulation gasket over discharge riser
and temporarily secure to pump housing cover with
adhesive tape.
NOTE: This must be done before fitting pumpset
to riser as the Cathodic Insulation gasket may not
fit over the pumpset.
Figure 5 Figure 6
6. To help prevent damaging wires during
installation, fit the wire protection tube provided in
the Electrical Fitting Kit over wires and half way
into conduit (temporarily secure with adhesive
tape). See Figure 6
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. Fit discharge riser assembly to the pumpset with
appropriate thread sealant or tape. With the
pumpset stationary, screw discharge riser into
pumpset ensuring 8 full threads minimum
engagement. The end of the thread of the discharge
riser must completely overlap the three set screws
in the top of the pumpset. This fitting should be gas
tight.
10.Tighten (screw) discharge riser into pumpset until
both inlet centreline identification marks on the
pumpset are in line with the mark previously placed
on the edge of the pump housing cover. Check this
alignment with a stringline. Do not loosen (back off)
discharge riser to achieve angular alignment.
11.Check overall length of riser/pumpset from cathodic
insulation gasket to end of pumpset to ensure 5mm
(min) clearance to bottom (inside) of pump housing.
12.Using Loctite 243 or equal, fit the three set screws
in the top of the pumpset. Tighten set screws
against discharge riser.
NOTE: These screws must be tight
Figure 7
13.Lubricate the protruding conduit with light oil to
prevent galling when fitting the 1" NPT bored-
through compression tube fitting.
14.Fit the 1" NPT bored-through compression tube
fitting to the discharge riser assembly with
appropriate thread sealant or tape, ensuring 8 full
threads minimum engagement. This fitting must be
gas tight.
NOTE: Do not tighten nut at this stage. Once this
nut is tightened, the only way of removing the
Connector Housing from the discharge riser is by
cutting through this fitting and the conduit.
15.Carefully lift the pumpset/discharge riser assembly
into a vertical position.
NOTE: When raising or lowering the
pumpset/discharge riser assembly, take care not to
damage the pumpset, motor leads or conduit. Lift
carefully with slings, chains etc.
16.Carefully lower the pumpset/discharge riser
assembly into the pump housing making sure that
the pumpset does not bind or drag on the sides of
the pump housing.
WARNING
ER

9
NOTE: Before the pumpset/discharge riser
assembly is completely inside the pump housing,
remove the adhesive tape holding the cathodic
insulation gasket to the pump housing cover.
Carefully fit the cathodic insulation gasket to the
turret cover.
17.Fit pump housing cover to turret cover with
appropriate cathodic insulators/washers for bolts
and nuts. Align marks on pump housing cover and
turret cover. The seal between the pump housing
cover and the turret cover must be gas tight.
18.Check that the pumpset/discharge riser is
electrically insulated from the tank. If not insulated,
rectify as required.
19.Determine basic location and orientation of Junction
Box, DPS etc. Based on this determination,
assemble Electrical Fitting Kit (Australian
Certification only) and DPS as follows:
NOTE: Do not use tape or sealant on NON-GAS
electrical connections.
a) Remove Junction Box cover.
b) Fit DPS to Junction Box (For Junction Boxes
which are not fitted with a 1/2" NPT(F) thread, use
adaptor supplied) Take care when fitting to avoid
damaging electrical leads.
c) Fit 25mm hex nipple to Junction Box.
d) Fit 25(F)M side of wire seal to hex nipple.
e) Fit 3/4" NPT compression tube fitting to 3/4"(F)
NPT side of wiring seal.
f) Fit 25mm plug/s to unused Junction Box port/s.
g) Fit 25mm barrier gland to Junction Box.
20.Fit duplicate pumpset/motor identification tag over
motor leads and over conduit as shown in Figure 7
21.Remove adhesive tape from wire protection tube
and slide tube off motor leads.
22.Slide wire protection tube half way into 3/4" NPT
compression fitting. See Figure 7
23.While holding the wire protection tube in place,
carefully slide the motor leads through the wire
protection tube and into the Junction Box.
24.Test the resistance from each lead to the conduit to
ensure that they are electrically insulated. Rectify
any fault as required.
25.Mount Junction Box to insulated support bracket if
required.
NOTE: If Junction Box requires a support
bracket, this must be electrically insulated from the
turret cover and tank.
26.Trim excess wire from motor leads and DPS leads
(leave adequate length for connection without
tension).
27.Individually cap the free ends of the leads with
insulating tape ensuring that the cores are covered.
28.Coil the leads in the Junction Box.
29.Fit cover and gasket to Junction Box.
3.2.8 Discharge Pipe Fittings
1. A DN25 (min) full bore pneumatically actuated
ball valve is required immediately downstream of
the Discharge Riser to isolate the discharge line.
2. After this ball valve, a DN25 (min) branch is
required for connection to the EBSRAY Inline
RV18-NRV Bypass Valve.
3. A port is required in the discharge line to accept an
isolation valve. This valve is for isolation of the
pressure gauge and the high pressure side of the
DPS.
4. The line from the valve must be fitted with a 'Tee'
arrangement to connect to a 0-2500kPa (0–25
Bar) pressure gauge and to the high pressure side
of the DPS via a 1/4" OD SS tube.
3.2.9 DPS (Differential Pressure Switch)
1. Fit the high pressure side 1/4" tube as mentioned
in 4 above.
2. A low pressure side (vapour pressure) port must be
provided through the Pump Housing Cover. This
port is required to accept a valve for isolation of the
pressure gauge plus the 1/4" tube fitting for the low
pressure side of the DPS.
3. The line from the valve must be split with a 'Tee'
arrangement. One side of the 'Tee' feeds an inlet
pressure gauge (0-2500 kPa) (0 –25 Bar) and the
other side feeds the low pressure side of the DPS
via a 1/4" OD SS tube.
NOTE: If positioning any components other than
as stated above, ensure that they are electrically
insulated from the turret cover, tank etc.
3.2.10 Bypass Valve
1. Fit Bypass Valve into bypass line ensuring correct
orientation i.e. flow is 'IN' from pumpset discharge
line and 'OUT' returns to tank.
2. Flow from Bypass Valve returns to tank vapour
space via a DN25 (min) line. A DN25 (min) full bore
pneumatically actuated ball valve and a DN20
(min) excess flow valve are also required to be
fitted to the bypass line.
3. The Bypass Valve return line must be electrically
insulated from the tank/turret cover. A hydrostatic
relief valve must be fitted in this line as the Bypass
Valve RV18 NRV is also a back-check valve.
3.2.11 PPVVALVE (Positive Pressure Ventilation
Valve)
A. Internal Mounting: The EBSRAY PPVValve
'Internal Mounting Kit' is intended for installation
inside the tank, but outside the pump housing wall.
Ensure that the inverted 'U' tube is no more than
50mm from the underside of the turret cover and
remains in the vapour space of the tank at all
times. A secondary shut off valve must be installed
between pump housing and the PPVValve and
must be operable from above the turret cover.
NOTE: PPV

Valve must be mounted in a vertical
position with the arrow pointing up and away from
the pump housing. i.e. flow path is only out from
the pump housing, into the tank vapour space.
B External Mounting: Alternate 'External Mounting'
is possible (e.g. retrofits to existing equalisation
pipes). However, it is still critical to ensure that
PPVValve is mounted vertically and that the
arrow points up and away from the side connected
to the pump housing. i.e. flow path is only out from
the pump housing, into the tank vapour space.

10
3.2.12 Leak Check
1. Tighten nut on 1" NPT bored through compression
fitting as shown in Figure 5
2. Remove cover and gasket from Junction Box.
3. Carefully raise Electrical Fitting Kit to expose the
motor leads and the top of the conduit. Take care
not to damage motor leads on the DPS pressure
lines. Seal off motor leads to conduit with adhesive
tape. Refer to Figure 8.
4. Leak check all conduit and other pressure
connections.
5. Remove tape from conduit, refit compression tube
fitting to conduit. Tighten nut on fitting as shown in
Figure 5
Figure 8
6. Refit cover and gasket to Junction Box
3.3 ELECTRICAL CONNECTIONS –PUMPSET AND SYSTEM
Important Electrical Installation Notes
1. All construction and installation is only to be carried out by suitably qualified personnel.
2. All construction is to be strictly in accordance with relevant Codes, Regulations, Standards, Directives
and site restrictions, as applicable to the site location.
3. EBSRAY Pump Controller is only to be installed in a non-hazardous area requiring IP55 (or less) rated
enclosures.
4. Particular care must be taken to ensure all items requiring earthing are adequately linked and
equipotentially bonded. e.g. Junction Box to Pumpset.
5. Motor earth is provided by a direct metallic connection from the Pumpset casing to the grounded
Junction Box.
Figure 9
DANGER

11
Typical electrical connections are as shown in the
accompanying diagrams Figure 9 and Appendix C.
Items provided by EBSRAY are suitable for use in the
specified intended areas. Ensure that any substitute
equipment supplied by others is certified and/or correct
for the intended usage and location. Following is a brief
description of the electrical wiring installation.
Installer must provide additional items as shown in
Appendix C –Typical Wiring Schematic and
Connection Diagram
NOTE: All gland, conduit, wiring terminations and
connections are to be strictly in accordance with
manufacturers instructions and relevant
Standards, Codes, Regulations and Directives
3.3.1 Junction Box
The Junction Box houses all electrical terminations
between the Pumpset, the DPS and the Pump
Controller.
The Pumpset (motor) has five (5) colour-coded leads:
a) Motor
Three (3) leads: Black, Red, Orange, are from the
motor windings and must be connected
respectively as a,b,c (clockwise) phase sequence
for correct direction of rotation - to terminals One
(1), Two (2) and Three (3) in the Junction Box.
b) Temperature Switch
Two (2) Blue leads are interchangeable and
connect to terminals Four (4) and Six (6) in the
Junction Box.
3.3.2 DPS (Differential Pressure Switch)
The Zone 1 Compliant Differential Pressure Switch
(DPS) has Four (4) leads: Blue, Black, Red and Green.
Connect Blue (Common) and Black (N.O.) leads to
Junction Box terminals Four (4) and Five (5)
respectively. Cap off Red lead (N.C.) by connecting to
terminal Eight (8) in the Junction Box. Connect Green
lead (Ground) to ground terminal in Junction Box.
3.3.3 Connecting Cable
The connecting cable between the Zone 1 Compliant
Junction Box and the Pump Controller is a six (6) core
plus ground, compliant cable - 2.5mm2(min) The
ground core must be connected to the Junction Box
ground terminal.
3.3.4 Pump Controller
The Pump Controller houses all electrical terminations
between the main switch board and the Zone 1
Compliant Junction Box. Refer to wiring diagram in
conjunction with following instructions.
1. Connect incoming isolated 3 phase power leads to
L1, L2, and L3. Connect the incoming Neutral to
Terminal N. Connect the Dispenser’s Normally
Open Voltage Free contact leads to Terminals 1
and 2. Connect a suitable Ground to the Earth
Terminal.
2. Activate power to Pump Controller (Pumpset motor
wiring should NOT be connected at this stage).
Check incoming phase sequence, ensure that L1,
L2, L3 is abc (clockwise) sequence.
3. Isolate power from Pump Controller.
4. Connect leads from cable to terminal strip in
Junction Box (see Figure 9) then refit Junction Box
cover and gasket.
5. Remove Plug from wiring seal, dam and fill with
compound provided, as per instructions. Refit Plug.
6. The wiring from the Junction Box is connected to
the Pump Controller as follows: Cores One (1), Two
(2) and (3) are connected to terminals T1, T2 and
T3 respectively on the motor overload relay. Cores
Four (4), Five (5) and Six (6) connect to Terminals
One (1), Three (3) and Four (4) respectively on the
terminal strip in the Pump Controller (Any extra
unused cores should be capped off). The ground
core is connected to the Earth Terminal.
SECTION 4 –OPERATION
4.1 DESCRIPTION
The RX33 Pumpset is designed to provide trouble-free
& safe operation in potentially explosive environments
provided it is operated in accordance with the following
recommendations.
1. Pumpset
The EBSRAY Model RX33 pumpset is a compact
close-coupled Submersible Regenerative Turbine
Pump/Motor unit, designed for pumping LPG of
Internationally accepted (ISO) quality and specification.
The Pumpset meets the requirements of European
ATEX and other International Standards and Codes for
use in potentially explosive atmospheres.
2. Motor
The Submersible Electric Motor is designed to meet
the requirements of European ATEX and other
International Standards and Codes. The motor is
Certified for the specified area and application (See
APPENDIX F). (Refer maximum starts per hour
WARNING this section)
Severe internal damage to
the pumpset will result if
unauthorised or uncontrolled
resetting occurs after any fault symptom is
indicated on the Pump Controller. Before
resetting, correct the fault. Refer to Trouble
Shooting Section 7.
Warranty will be void if unauthorised
resetting is conducted without first
correcting the fault.
4.2 LUBRICATION
No 'in service' lubrication is required on EBSRAY's
Model RX33 Pumpset.
4.3 PRE-STARTUP CHECKLIST
Record pre-start inspection on checklist (Appendix D)
1. Check that all electrical wiring is insulated from the
ground, conduits, tank etc.
2. Check for leak-free installation at Pumpset, pipe
and electrical conduit connections.
WARNING
ER

12
3. Direction of rotation - This MUST be tested prior
to Pumpset operation by using a Phase
Sequence Indicator at the Pump Controller.
With Pumpset wiring at the Junction Box in the
order: BLACK (1), RED (2), ORANGE (3), the
power supply phase sequence must be a, b, c. (or
R,S,T.) (CLOCKWISE)
Do not run Pumpset in
reverse. Severe internal
damage to the Pumpset may result.
4.Ensure supply voltage is correct and that all
relevant electrical components are compliant &
adequate for the application.
Do not run Pumpset dry.
Severe internal damage
to the Pumpset will result, voiding Warranty.
5. Valves should be in the following positions:
(see Appendix A –P&ID for locations)
Pump Housing Inlet Valve.........................OPEN
PPVIsolation Valve.................................OPEN
Valves to both sides of DPS......................OPEN
Valves to both Pressure Gauges...............OPEN
Discharge Line Valve/s..............................OPEN
Vapour/Bypass Return Line Valve/s ........OPEN
Do not start Pumpset
against closed discharge
valve or with Pump Housing Inlet Valve
closed or throttled.
6. Ensure that Pumpset is LPG liquid filled by
removing all vapour in an approved manner from
the Pumpset Discharge Riser.
7. Back off Bypass Valve Adjusting Screw fully i.e.
minimum differential pressure.
8. Ensure DPS bypass time in PLC is set to required
minimum delay time for the site (See Section
5.3.2)
9. Ensure ‘Run-On’ feature is enabled/disabled as
required for the site (See Section 5.3.3)
Exceeding 20 starts per
hour OR re-starting in
less than 2 minutes after the last start may
result in severe and permanent internal
electrical damage to the motor.
10. Ensure Keyed ‘RUN-OFF-TEST’ Selector switch
on Pump Controller is ‘OFF’
11. Ensure circuit breaker (Q1) in Pump Controller is
‘OFF’.
12. Ensure MOL Current Cut-Out Selector is set to
FLA rating (see Appendix B or C) and MOL Reset
Selector is in automatic reset mode –position (A).
4.4 STARTUP PROCEDURE
A Pumpset Run Log is provided in Appendix E. Fill in
the startup section of the log as indicated below.
For commissioning and testing it may be advantageous
for two persons, with some means of communication,
one stationed at the Pump Controller and the other
stationed at or near the pumpset location.
1. Check readings on both pressure gauges. Note any
difference in static readings as this will have to be
taken into account when setting Bypass Valve.
Record vapour pressure in the commissioning
section of the Pumpset Run Log.
2. Connect amp meter to Pump Controller lead(s) T1,
T2 or T3 outside Hazardous Area
3. Activate power to Pump Controller.
4. Switch "ON" Q1 circuit breaker in Pump Controller.
5. Turn key switch to 'TEST' at Pump Controller.
This will start Pumpset. (If any aspect of the
Pumpset or pumping system does not function
properly, immediately turn the keyswitch to 'OFF'
and rectify the problem).
6. Check system functionality, Pumpset should
immediately begin to build differential pressure up
to approximately 500 - 600 kPa. (5 –6 Bar)
Record discharge pressure in the commissioning
section of the Pumpset Run Log.
7. Check that current reading is below FLA rating (See
Appendix B or C) on T1, T2, & T3.
Record T1, T2, & T3 current readings in the
commissioning section of the Pumpset Run Log.
8. Ensure that liquid is flowing through Bypass Valve.
This should be detectable audibly (by listening) or
by feeling the valve/pipework (by hand).
9. Screw in the Bypass Valve Adjusting Screw not
exceeding two turns per minute until a differential
pressure of 700 kPa (7 Bar) is achieved.
NOTE: During this procedure check current at
Pump Controller on T1, T2 & T3 (Must not exceed
Motor FLA rating - See Appendix B or C)
10. When 700 kPa (7 Bar) differential pressure is
reached, turn Pumpset off and leave off for
approximately 1 minute.
11. Restart Pumpset in 'TEST' mode. Note differential
pressure reading. This may be slightly different to
when first set (This is a normal characteristic of
Bypass Valve operation when first set in this
manner).
12. Reset differential pressure as required (do not
exceed 700kPa (7Bar) @ 50Hz at this stage).
Record discharge pressure and T1, T2, & T3
current readings in the commissioning section of
the Pumpset Run Log.
13. The Pumpset is now ready for automatic (dispenser
actuated) operation via terminals 1 and 2. Turn
keyswitch on Pump Controller to ‘RUN’ mode. The
Dispenser/Communication System will now initiate
the running of the Pumpset.
NOTE: Running-in Period - Due to the precision
manufacturing tolerances and the nature of the
sleeve bearing material, the Pumpset may need to
be run-in at 700kPa (7 Bar) for a period of time
before the maximum differential pressure setting of
the Bypass Valve may be reached.
14. After the run-in period, differential pressure can be
set to maximum (Do not exceed FLA rating of
Motor - refer Appendix B or C). This differential
pressure is dependent upon setting required by
end user. Record any changes to the discharge
pressure in the Pumpset Run Log.
Do not exceed full load
Amps on any leg of Motor.
15. After any Bypass Valve adjustment, tighten
adjusting screw locknut and wire in place for
security.
WARNING
ER
WARNING
ER
WARNING
ER
WARNING
ER
WARNING
ER

13
16. The startup procedure is now complete for the
RX33 Pumpset and Protection System.
17. Inspect Pumpset/pumping system frequently during
the first few hours of operation, then periodically
thereafter. Record observations from these
inspections in the Pumpset Run Log .
a) Inspect the pumping system checking for LPG
leaks, vibration, unusual noises, etc.
b) Check the tank vapour pressure and the system
discharge pressure.
c) Check L1, L2 and L3 current, voltage and
balance between phases.
d) Check Pumpset run hours.
e) Check temperature of LPG in tank.
NOTE: Dispensing/pumping may be interrupted
(Pumpset stopped) by DPS fault during tanker
unloading operations. Resetting the RX33 must
only occur after unloading operation is completed
and the LPG in the storage tank has stabilised to
the new state/mix/temperature conditions - without
boiling. This condition represents a characteristic
of LPG handling and not caused by the Pumpset or
pumping effects
SECTION 5 –PUMP CONTROLLER
Figure 10
All control voltages within
the Pump Controller are
220/240 Vac
Turning the ‘RUN-OFF-
TEST’ Keyed selector
switch to the ‘OFF’
position, or switching Circuit Breaker Q1 ‘OFF’
does NOT isolate all electrical supplies to the
hazardous area. The installer MUST provide an
isolator and an emergency stop circuit that cuts
all supply to the Drive. All power to the Drive
must be cut before working on any of the
subsequent equipment in the hazardous area.
Door Latch Key and/or
‘RUN-OFF-TEST’ key
should only be accessed by suitably trained and
qualified personnel (e.g. Service Maintainer)
NOTE: ‘VIEW SETTINGS AND LOGS’ Push
Button may be operated without the need to have
key access.
NOTE: This publication is specific to the L861002
Series of Pump Controllers. Ebsray offers
alternative pump monitoring and control equipment
for various applications/markets. Refer to IOM
supplied with the alternative Ebsray pump
monitoring and control equipment as required.
Contact your Ebsray authorised representative for
details.
Table 2 –Pump Controller Components
Item
Description
1
Lockable Enclosure Latch
2
‘RUN-OFF-TEST’ Keyed Selector Switch
3
‘RESET’ Push Button
4
‘View Settings and Logs’ Push Button
5
PLC with LCD Screen (see Section 5)
6
Motor Contactor –KM1
7
Motor Overload Relay –F1
7A
MOL Current Cut-Out Selector
7B
MOL Reset Selector: Manual (H) –Automatic (A).
Note: This must be set to the Automatic (A) Reset
Position
8
Circuit Breaker (Isolator) –Q1
9
Run Relay –KA1
10
Terminal Strip
DANGER
DANGER
CAUTION
DANGER

14
5.1 DESCRIPTION OF PUMP CONTROLLER
The L861002 Series of Pump Controllers are
designed to manage the RX Series Submersible
Pumpsets and pumping system as described in
Appendix A. There are three primary functions of the
Pump Controller:
–Normal operation,
–Pumpset/Pumping System Fault Detection and
Pumpset Protection Functions
–Pumpset/Pumping System Diagnostics
5.2 ACTIONS
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
their symbol or symbol plus Enter or
Shift
Default screen upon power up.
5.2.2 To Set Date & Time
Time & Date will appear in the format
HH:MM DD/MM/YYYY
Press the Shift + buttons
The display will flash on the Hours to be changed
Press or to decrease or increase value.
Press to move to Minutes
Press or to decrease or increase value.
Press to move to Day
Press or to decrease or increase value.
Press to move to Month
Press or to decrease or increase value.
Press to move to Year
Press or to decrease or increase value.
Press Enter to save settings
5.2.3 To Set DPS Time (Max 45s)
Press to show Status Settings screen
Press the Shift + buttons (Display Flashes)
Press or to decrease or increase value. (in
1/100s)
Press Enter to save setting
5.2.4 To View Settings & Set ‘Run-On’ Time
(Valid Options 0 or 2mins)
Press to show Status Settings screen
Press to toggle between 0 or 2
Press to save setting and return to Main Screen
5.2.5 View Logs
Press to toggle through the three Log Screens
5.2.6 To Reset a Critical Fault
NOTE: A critical fault cannot be reset unless
the Fault Screen displays ‘Reset Allowed’.
Switch the ‘RUN-OFF-TEST’ switch to the ‘OFF’
position
Press ‘RESET’ Push Button on door.
The normal ‘Pump Ready to Run’ screen will be
displayed.
Switch the ‘RUN-OFF-TEST’ switch to the ‘RUN’
position
5.3 NORMAL OPERATION
5.3.1 ‘RUN’
–When the key-switch is in ‘RUN’, the Pump
Controller starts/stops the Pumpset automatically
when a normally open, voltage free contact signal
from the dispenser(s) closes/opens.
5.3.2 DPS Bypass Timer
The Pump Controller features an adjustable timer (0
to 45 seconds) that enables the Pumpset to start and
run for a period of time, overriding the DPS. This
allows the Pumpset time to build up pressure on start-
up without indicating any fault. The timer is factory set
to 12 seconds and can be adjusted (only if absolutely
required) to suit site conditions, e.g. long discharge
line to the dispensers. (See Section 5.2.3 for
Adjustment Procedure). When the Pumpset starts,
the Pump Controller displays ‘DPS Time’ in seconds.

15
This time displayed is the actual time it has taken for
the Pumpset to build the minimum required differential
pressure after each re-start.
5.3.3 ‘Run-On’ Time
The Pump Controller has a 2 minute ‘Run-On’ feature
which can be enabled/disabled as site conditions
dictate. When the ‘Run-On’ feature is enabled, the
Pump Controller will continue to run the Pumpset for a
minimum of 2 minutes after the initial run signal from
the dispenser.
The ‘Run-On’ feature protects the Motor from the
potentially damaging effects of rapid starting/cycling
typically caused by short (less than 2 minute) vehicle
fill times (Note: maximum 20 starts per hour for the
Motor). If the site condition’s average fill time of the
vehicle is less that 2 minutes, then the ‘Run-On’
feature should be enabled. The ‘Run-On’ feature is
factory set to disabled. Turning the key-switch to the
‘OFF’ position will stop the Pumpset regardless of
the ‘Run-On’ feature being enabled or disabled. (See
Section 5.2.4 for the ‘Run-On’ enable/disable
procedure). The status of the ‘Run-On’ feature can
be determined on either the ‘STATUS SETTINGS’
Screen or on the ‘PUMP RUNNING’ Screen.
5.3.4 ‘TEST’
When the key-switch is in ‘TEST’ position, the Pump
Controller starts the Pumpset independently of the
dispenser’s run signal. The Pumpset will continue to
run until the key-switch is turned to the ‘OFF’ position.
While the Pumpset is running in ‘TEST’, all other
features of the Pump Controller are the same as in
‘RUN’, with the exception of the ‘Run-On’ feature.
The ‘TEST’ feature is ONLY to be used to aid start-
up/commissioning maintenance procedures e.g.
setting the bypass pressure.
Under no circumstances
is the Pump Controller to
be left in ‘TEST’ mode for conventional filling.
5.3.5 Normal Operation PLC Displays
Indicates the Pumpset is
idle and ready to run.
The time and date are
also displayed. (See
Section 5.2.2 to set the
time and date).
Indicates the Pumpset is
running. The 2nd line
displayed indicates the
actual time it has taken
for the Pumpset to build
the minimum required
differential pressure
after each re-start. The
3rd line displays the actual time that the pumpset has
been running since the last start. The 4th line
indicates the status of the 2 minute ‘Run-On’ feature:
Run-On Time=00002Min Indicates feature is enabled.
Run-On Time=00000Min Indicates feature is disabled.
5.4 PUMPSET/PUMPING SYSTEM FAULT
DETECTION & PROTECTION FUNCTIONS
If the Pump Controller detects that one of the
parameters of the Pumpset or the Pumping System is
operating abnormally, the Pump Controller will stop
the Pumpset and indicate a fault warning on the LCD
screen (See Troubleshooting for Evaluation and
Rectification of all indicated Faults).
The faults are divided into the following groups:
5.4.1 Critical Faults
If the Pump Controller detects a Critical Fault, the
operation of the Pumpset is immediately halted. The
Pumpset cannot be restarted again until an
authorised person (e.g. a service/maintenance
technician) has a) evaluated the cause of the fault, b)
rectified the fault and c) if appropriate and safe to do
so, reset the Pump Controller via the PLC’s ‘Reset’
button on the door of the enclosure. (See Section
5.2.6 for the Fault Reset Procedure).
Critical Faults that can be detected are:
5.4.1.1 DPS Faults Pump Controller monitors the
DPS while the Pumpset is running.
Indicates the Pumpset
has not developed the
minimum required
differential pressure
before the DPS Time
has elapsed. The Pump
Controller can be reset
after the reason for the
Fault has been evaluated and rectified.
Indicates the Pumpset
has not maintained the
minimum required
differential pressure
after the DPS Time has
elapsed. The Pump
Controller can be reset
after the reason for the
Fault has been evaluated and rectified.
5.4.1.2 MOL Faults Pump Controller monitors the
current draw of the Pumpset’s Motor via the Motor
Overload (MOL) relay while the Pumpset is running.
Indicates the Pumpset’s
current draw has
exceeded the maximum
allowable amperage
tripping the MOL relay. It
is not possible to reset
the Pump Controller
because the MOL relay
has not yet automatically returned to the normally
open position. Indicates the fault as
described above,
except the MOL relay
has automatically
returned to the normally
open position. The
Pump Controller can be
reset after the reason for the fault has been evaluated
and rectified.
Indicates a locked rotor
Motor current or short
circuit condition at
startup.
DO NOT reset this Fault
unless other means have
been employed to ensure
that the cause of this Fault has been rectified.
WARNING
ER
WARNING
ER

16
5.4.1.3 HBT Faults The Pump Controller monitors
the Pumpset’s Bearing Cooling and Lubrication
(BCL) liquid temperature via the High Bearing
Temperature (HBT) switch, embedded in the Motor.
Indicates that the
Pumpset’s BCLliquid
has exceeded the
maximum allowable
temperature while the
Pumpset is running,
tripping the HBT switch.
It is not possible to reset the Pump Controller
because the HBT switch has not yet automatically
returned to the normally closed position.
Indicates the fault as
described above except
the HBT switch has now
returned to it’s normally
closed position. The
Pump Controller can be
reset after the reason for
the Fault has been evaluated and rectified.
5.4.2 Preventative Faults
The Pump Controller has
detected a low tank level
via a normally open, Low
Tank Level switch (if
fitted). The Pump
Controller will allow the
Pumpset to run after the
storage tank is refilled and the Low Tank Level switch
opens. No other action is required.
5.4.3 Informative Faults
Indicates that the liquid
in the Storage Tank has
exceeded the maximum
allowable temperature
while the Pumpset is
NOT running, tripping
the HBT switch. The
Pump Controller will not allow the Pumpset to start
until the HBT switch automatically returns to its
normally closed position.
Indicates the fault as
described above except
the HBT switch has
returned to its normally
closed position. The
Pump Controller will
allow the Pumpset to
start normally without a reset of the Pump Controller.
NOTE: After this fault has occurred, the normal
‘PUMP RUNNING’ screen will be displayed while
the Pumpset is running. However, when the
Pumpset is stopped, the screen above will be
displayed again to alert the service/maintenance
technician that the event has occurred at some
earlier time.
5.5 PUMPSET/PUMPING SYSTEM DIAGNOSTICS
The Pump Controller stores various information in the
PLC which is useful for system diagnostics,
maintenance, troubleshooting, etc. This information is
displayed on the PLC’s LCD screen and can be
accessed from either the ‘View Settings and Logs’
push button on the front of the enclosure or by the
buttons on the front of the PLC, internal to the
enclosure. (See Section 5.2.4 & 5.2.5 for the Viewing
Settings and Logs Procedures).
The information that is stored and can be viewed is:
The ‘Settings’ screen
displays the current
DPS time setting (See
Section 5.2.3) and the
status of the 2 minute
‘Run-On’ feature (See
Section 5.2.4).
Run-On Time=00000Min Indicates feature is disabled.
Run-On Time=00002Min Indicates feature is enabled.
The 1st Log screen
displays the Pumpset’s
total run hours.
NOTE: In the event the Pumpset is changed, the
displayed Run Time at change-out must be
recorded.
The 2nd Log screen
displays the number of
specific MOL, DPS or
HBT Faults and the
time (in hours and
minutes) since the last
Fault.
NOTE: Only one type of specific fault will be
recorded should two successive faults occur. The
Pump Controller will only record the last type of
fault. If this type of fault is repeated, the PLC will
continue to record the accumulated number of
this type of fault, until a different type of fault is
recorded.
The 3rd Log screen
indicates:
- the number of Pumpset starts per hour for the
current hour.
- the maximum number of Pumpset starts per hour
in the last 24 hours
- the maximum number of Pumpset starts per hour
during the life of the Pumpset.
NOTE: 20 starts per hour or more in any of
these ‘Starts per Hour’ Logs indicates the
potentially damaging effects of rapid starting and
cycling which must be rectified (See Section
5.3.3).

17
SECTION 6 –MAINTENANCE
Prior to any system
disassembly or service,
verify that all requirements of relevant Codes,
Regulations, Standards or Directives are met and
that specific site requirements etc are satisfied.
6.1 INSPECTION
Periodic Inspection of the Pump System and Ancillary
Equipment is recommended. EBSRAY recommend a
maximum interval of three months or 500 hours
operation between routine periodic maintenance
inspections (More frequent inspections may be
necessary dependent upon usage, site conditions,
operation etc).
Check:
a) Inspect the Pumping System checking for
LPG leaks, vibration, unusual noises, etc.
b) Check the tank vapour pressure and the
system discharge pressure.
c) Check L1, L2 and L3 current, voltage and
balance between phases.
d) Check Pumpset run hours.
e) Check temperature of LPG in tank.
If any condition is considered to be of an urgent or
critical nature, consult your service provider or your
EBSRAY representative immediately. Record
observations in the Pumpset Run Log, Appendix E.
6.2 SERVICE
a) RX33 Pumpset
The RX33 Pumpset is an integrated unit which includes
a Certified explosionproof Electric Motor.
Pumpset overhaul/repair
can ONLY be conducted
by certified/qualified repairers of explosion
protected electrical equipment and in addition, who
have been trained and approved by EBSRAY.
The RX33 Pumpset is designed to enable complete
overhaul if required.
Complete information regarding overhaul and repair of
RX33 Pumpsets is available to certified repairers
trained and approved by EBSRAY.
NOTE: Warranty will be void should unauthorised
disassembly be conducted.
b) Pump Controller and Ancillary Equipment.
All equipment supplied by EBSRAY can be serviced by
competent (qualified) persons, or returned to EBSRAY
for Factory Service.
Refer to specific equipment manufacturer’s Service
Instructions to ensure correct maintenance procedures.
NOTE: Pump Controller is fitted with a factory
coded PLC. This item must maintain its original
logic to perform its operating function correctly.
Refer to EBSRAY for specific information and
instructions. Tampering with or modifying PLC
logic will void Pumpset Warranty.
6.3 SERVICE EXCHANGE
EBSRAY maintains RX33 Service Exchange Pumpsets
to facilitate rapid and economical changeover should
the need arise. Contact EBSRAY or your local
representative to arrange.
(An EBSRAY Service Exchange Pumpset is a fully
reconditioned, ‘as-new’ performance, Factory
Warranted item which has been in service prior to its
return for overhaul.)
6.4 SPARE PARTS
All Spare Parts for the RX33 Pumpset, Pump Controller
and/or Ancillary Equipment are readily available. (refer
to SERVICE above relating to restrictions as to the
extent of overhaul/repair only by certified/qualified
persons)
A spare parts listing is available to certified overhaulers
or repairers trained and approved by EBSRAY.
CAUTION
DANGER
DANGER

18
SECTION 7 –TROUBLESHOOTING
Error
Condition
Possible
Problem
Possible Cause
Remedy
Differential
Pressure too low
Insufficient LPG in Storage Tank
Fill Storage Tank
Incorrect Bypass Valve setting.
Adjust (Increase) Bypass Valve
setting to achieve required
differential pressure.
Bypass Valve jammed open
Check Bypass Valve, remove any
obstruction, roughness, corrosion
etc.
Pumpset has 'Dead Headed'
-Restriction in discharge system or
bypass line e.g. Discharge
Isolation Valve, Bypass Valve,
Bypass EFV or Isolation Valve
closed
Check all devices in the discharge
system and bypass line, remove
blockage, repair or replace as
required
Excessive inlet restriction
- Inlet Isolation Valve not opened
fully
- Faulty Inlet Excess Flow Valve
Check / open Inlet Valve
Check, repair or replace Inlet
Excess Flow Valve as required
Tanker unloading into Storage
Tank during dispenser operation
Wait until unloading operation is
completed and mix/temp/state has
stabilised in tank
Insufficient liquid in Pump Housing
- PPVValve not fully open
Open PPVValve Isolation Valve
Normal wear after extended
service
Reconditioning (certified persons
ONLY) or Service Exchange
Pumpset required.
Power supply to Pumpset faulty
e.g.
- low/high voltage
- loss of phase
- imbalance of phases
- etc
Check power supply (with
Pumpset running and with
Pumpset stopped):
a) To Main Switch Board
b) To Pump Controller
c) To Pumpset
Contact(s) or coil in Motor
Contactor (KM1) faulty
Check Contactor, repair or replace
as required
DPS not
functioning or
unable to function
correctly
Isolation Valves (low side and/or
high side) to DPS not open
Open both Isolation Valves to DPS
DPS Sensor Lines damaged
Repair or replace Sensor Lines
Discharge Valve not fully open
Check Actuator/
open Discharge Valve
Incorrectly adjusted DPS
Check DPS as per manufacturer's
instructions
Faulty DPS
Replace/repair DPS
Control Circuit not
functioning
correctly
Circuit/Communications outside
Pump Controller faulty
Check Circuit/Communications,
repair or replace as required
Cables / connections between
Main Switch Board, Pump
Controller and DPS faulty
Check cables/connections, repair
or replace as required
Pump Controller faulty
See ‘Pumpset Will Not Run’ below
*** DPS FAULT ***
AFTER DPS BYPASS
TIME HAS ELAPSED

19
Error
Condition
Possible
Problem
Possible Cause
Remedy
Pumpset has not
reached minimum
differential
pressure. before
DPS bypass time
has elapsed.
Insufficient LPG in Storage Tank
Fill Storage Tank
Excessive inlet restriction
- Inlet Isolation Valve not opened
fully
- Faulty Inlet Excess Flow Valve
Check/open Inlet Valve
Check, repair or replace Inlet
Excess Flow Valve as required
Incorrectly adjusted DPS
Check DPS as per manufacturer's
instructions
Faulty DPS
Replace/repair DPS
DPS Bypass
Timer set too low
for site conditions
Long discharge line to Dispenser
No liquid in discharge line e.g.
drained back through Dispenser's
Vapour Return or 'boiled off'
Extended delays between
Pumpset starts
Increase DPS Bypass Timer to
suit site conditions (see Operating
Instructions for timer adjustment)
Note: Always set the DPS Bypass
Timer to the MINIMUM time
required for the site conditions
Differential
Pressure too low
See DPS above
See DPS above
Normal wear after extended
service
Reconditioning (certified persons
ONLY) or Service Exchange
Pumpset required.
OR
Differential
Pressure too high
- no flow or very
low flow through
Pumpset
Restriction in discharge system or
bypass line e.g. Discharge
Isolation Valve, Bypass Valve,
Bypass EFV or Isolation Valve
closed
Check all devices in the discharge
line or the bypass line. Adjust
(decrease) Bypass Valve setting,
repair or replace as required
Restricted or
blocked BCL
Breathers/Filters
Dirt/debris/contaminated LPG in
Storage Tank or Pump Housing
If Pumpset will not run after reset,
contact EBSRAY or Appointed
Representative
Control Circuit not
functioning
correctly
Circuit/Communications outside
Pump Controller faulty
Check Circuit/Communications,
repair or replace as required
Cables/connections between
Main Switch Board, Pump
Controller and Pumpset (HBT
switch) faulty
Check cables/connections, repair
or replace as required
Fault in Pump Controller
See ‘Pumpset Will Not Run’ below
Excessive
Pumpset Starts
(more than 20
starts per hour)
OR repeated re-
starting in less
than 2 minutes
after last start
Too frequent repeat run signals
from Dispenser (may be faulty
signal cycling)
Limit number of starts. (See Pump
Controller –Section 5)
Check/repair dispenser signal
quality as required.
Control circuit/Pump Controller
malfunction. (Run Relay cycling)
See ‘Pumpset Will Not Run’ below
Excessive manual resets of Pump
Controller after faults
Remedy problem before resetting.
Pumpset
recirculating
continuously
Pump Controller left in ‘Test
Mode’, recirculating to tank and
increasing the LPG temperature
Switch Pump Controller to ‘Run
Mode’
OR
High liquid
temperature in
Storage Tank
High liquid temperature when
delivered
Allow liquid in tank to cool over
time. Top up to maximum
allowable level with cool LPG.
or
Refer to EBSRAY
Pumpset running continuously for
extended period - ensure that key
is not left in "TEST" position.
Overheating in
‘Bypass Mode’
Insufficient LPG in Storage Tank..
Fill Storage tank.
PPVValve not
functioning
correctly
PPVIsolation Valve not open
Open PPVIsolation Valve
Blocked or faulty PPVValve
Inspect PPVValve, replace if
faulty
Pumpset
recirculating
continuously
Pump Controller left in ‘Test
Mode’, recirculating to tank and
increasing the LPG temperature
Switch Pump Controller to ‘Run
Mode’
*** HBT FAULT ***
WHILE PUMP RUNNING
& SWITCH NOT RESET
Reset not allowed
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH NOT RESET
Run not allowed
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH IS RESET
Pump RUN allowed
*** HBT FAULT ***
WHILE PUMP RUNNING
& HBT SWITCH RESET
Reset allowed
*** DPS FAULT ***
BEFORE DPS BYPASS
TIME HAS ELAPSED

20
Error
Condition
Possible
Problem
Possible Cause
Remedy
MOL Relay set too
low
Incorrect setting on MOL Relay
Reset MOL setting to FLA of
Motor as per Specification (See
Section 4.3)
OR
Differential
Pressure too high
Incorrect Bypass Valve Setting.
Adjust (decrease) Bypass Valve
setting to achieve required lower
pressure, not exceeding FLA.
Pumpset has 'Dead Headed' -
restriction in discharge system or
bypass line e.g. Discharge
Isolation Valve, Bypass Valve,
Bypass EFV or Isolation Valve
closed
Check all devices in the discharge
line or the bypass line, remove
blockage, repair or replace as
required
Discharge Valve not fully open
Check Actuator and/or
Open Discharge Valve
Power Supply to
Pumpset faulty
Power supply to Pumpset faulty
e.g.
- low/high voltage
- loss of phase
- imbalance of phases
- etc
Check power supply (with
Pumpset running and with
Pumpset stopped):
a) To Main Switch Board
b) To Pump Controller
c) To Pumpset
Contact(s) or Coil in Motor
Contactor (KM1) faulty
Check Contactor, repair or
replace as required
Motor Overload Relay (F1) faulty
Check Motor Overload Relay,
repair or replace as required
Excessive
Pumpset Starts
(more than 20
starts per hour)
OR repeated re-
starting in less
than 2 minutes
after last start
Too frequent repeat run signals
from Dispenser (may be faulty
signal cycling)
Check/repair dispenser signal
quality as required.
Short fill times from Dispenser
Limit number of starts, i.e. enable
‘Run-On’ feature. (See Section
5.2.4).
Control circuit/Pump Controller
malfunction
(Run Relay cycling)
See ‘Pumpset Will Not Run’ below
Excessive manual resets of Pump
Controller after faults
Remedy problem before resetting.
Motor damaged
by excessive
Pumpset starts
(more than 20
starts per hour)
See Excessive Pumpset Starts
above
Reconditioning (certified persons
ONLY) or Service Exchange
Pumpset required.
Obstruction
causing Pumpset
to become
jammed.
Dirt/debris/contaminate lodged in
Pumpset (Impeller, Sleeve
Bearings, Rotor, etc)
Attempt to clear Pumpset,
Tank/Pump Housing. If Pumpset
will not run after reset, contact
Factory or Representative
Motor / Pumpset
Sleeve and/or
Thrust Bearings
damaged
Dirt/debris/contaminate in Storage
Tank and/or Pump Housing
Clean Storage Tank and/or Pump
Housing before refilling with clean
product
Normal wear after extended
service
Reconditioning (certified persons
ONLY) or Service Exchange
Pumpset required.
Control Circuit not
functioning
correctly
Fault in Pump Controller
See ‘Pumpset Will Not Run’ below
Short Circuit in
connecting wires
Damaged wires from Pumpset to
Pump Controller
Ensure no short-circuits in field
wiring –rectify as required.
Water/condensation causing
short-circuit at terminals or wires
Remove water/condensation
*** MOL FAULT ***
AFTER STARTUP &
SWITCH IS RESET
Reset is allowed
*** MOL FAULT ***
AFTER STARTUP AND
SWITCH NOT RESET
Reset NOT allowed
*** MOL FAULT ***
DURING STARTUP &
LOCKED ROTOR
Do NOT reset