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:
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WARNING
CAUTION
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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
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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
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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
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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
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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