EBARA DMLU Manual

Instruction and Operation Manual
Model DMLU
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Safety Information and Introduction
DMLU
Instruction, Operation, and Maintenance
Project: Model: Chk’d: Date:
Contents
Section Page
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warnings in this manual provide information for safe use of your EBARA pump, and instructions for preventing injury to those
operating it. Please pay close attention to the instructions listed below. If there are any questions regarding these instructions,
please direct them to EBARA INTERNATIONAL CORPORATION.
1. Before lifting the pump, confirm the total weight of the unit listed in the catalog or outline drawing. Use the appropriate
hoist or crane assembly, and make sure that the load is balanced to prevent shifting during loading and off-loading.
2. Be sure to keep the pump from lying on the power and control cables, and do not use the power and control cables
to lift the pump. This can result in damage to the cables and can cause electrical shorts that can possibly lead to
fires.
3. A qualified electrician should perform all wiring and all national and local electrical codes must be observed.
4. Make sure that all equipment is properly grounded. Failure to do so can result in electric shock.
5. Disassembly and repair of the pump should only be performed by factory trained service centers. Errors made by
unqualified personnel can result in improper assembly and operation, therefore resulting in possible injury.
6. Always make sure that power switch is in OFF position and that power cable is disconnected before inspecting or
repairing the pump.
7. If pump is to be out of service for a long period of time, turn power off. If power is left on without operating pump it
can cause insulation breakdown, resulting in a possible motor short or electric shock.
8. Do not insert hands into the pump during operation.
9. Do not operate the pump unsubmerged, as overheating can occur, causing insulation breakdown and possible
electric shock.
10. If the insulation resistance is below 1M
Ω , turn power off to unit as soon as possible, as electric shock can occur.
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DMLU
Delivery Checks
Project: Model: Chk’d: Date:
When your pump is delivered, check the following items immediately.
1. Pump and accessories
a.) Confirm that no damage has occurred during transportation.
b.) Confirm that all items have been delivered.
2. Nameplate
a.) The basic specifications of the pump are listed on the nameplate. Read the pump nameplate to confirm
that the pump you received matches the specifications that you ordered.
Fig. 1 – Pump Nameplate
Specifications
Item
Liquid handled Type
Temperature
Solids Capacity Discharge size (in.)
Solid size (in.)
Materials Impeller
Phase
Hz
Motor Voltage
Starting Method
Protector
Mechanical Seal Lubricants
Maximum water depth
Installation
Specifications
Waste water
0 - 40° C
3, 4, 6
3
Cast iron
Three Phase
60 Hz
230 or 460 VAC
2.2kW : Direct start
3.7 ~ 22kW : Star-Delta start
2.2kW : Auto-cut
3.7 ~ 22kW : Thermal Protector
Turbine oil ISO VG32
26 ft.
with Quick Discharge Connector or Floor mounted
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1. Before installation:
a.) Use a megger to measure the insulation resistance between the ground wire and each phase of the motor.
Keep the ground wire off the ground during measurement. The value of each reading should be more than 20
meg-ohms.
2. Installation:
a.) Using a chain or lifting cable assembly, lower the pump into the tank or wet well.
DO NOT USE THE POWER & SENSOR CABLE TO LIFT PUMP.
b.) Do not install the pump horizontally. Ensure that the pump is upright and on a secure base. Installation of pump
with Quick Discharge Connector (QDC) shall be in accordance with manual entitled “Quick Discharge Connector.”
c.) Install pump in a location within the tank that has the least amount of turbulence.
d.) Support the discharge piping to prevent vibration.
e.) Install proper ventilation so that air will not become stagnant.
f.) Do not permit the end of the discharge piping to become submerged, as it will result in backflow when the pump stops.
g.) Set control operating levels (i.e. floats) so that pump is not running for more than ten minutes with water level at
minimum operating level as indicated in below chart. Continuous operation of pump at minimum water level will
result in automatic cut-off switch in motor to be activated.
Figure 2
3. Electrical Wiring:
Note: All electrical wiring should be performed by a qualified electrician, and in accordance with all national
and local electrical codes. Incorrect wiring can result in serious injury.
Figure 3
a.) Wiring should be performed as indicated in Figure 3.
b.) Do not allow the end of the cables to become immersed in water.
c.) Make sure pump is properly grounded using the green ground wire in the power cable. Do not connect the
green wire to the power supply.
DMLU
Installation
Motor Size
(HP) 3 5 7.5 10 15 20 30
H2 (in) 219/16 2411/16 2713/16 2713/16 303/8303/8325/8
H1 (in) 11 11 119/16 119/16 1211/16 1211/16 1215/16
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DMLU
Installation (continued)
Project: Model: Chk’d: Date:
d.) Motor protection:
• For 3HP motors, a built-in auto-cut is used and will be activated when motor becomes overheated due to
abnormal conditions such as locked rotor or single phasing. There is no external wiring for this feature.
• For 5HP to 30HP motors, a normally closed built-in thermal protector is used. When motor winding becomes
over-heated, the circuit is opened, shutting the motor down and allowing it to cool. An external sensor cable
is provided for this feature and must be connected to a thermal relay in the control panel. Failure to do so
will void the warranty. Specifications for the thermal protector are listed below:
Contact rating: AC 230V, 13A (Max)
Contact type: Break contact (normally closed)
1. After completing installation, measure the insulation resistance again, using the procedure described in the
“Installation” section.
2. Check to make sure there is an adequate amount of water in the wet well. Continuous operation of the pump in a
dry condition will cause the motor protector to be activated.
3. Check the direction of rotation by turning on pump. If the discharge volume is low or unusual sounds are heard, it is
likely that rotation has been reversed. If this happens, reverse two of the three power cable wires. (see Figure 4)
Figure 4
4. After confirming that the direction of rotation is correct, gradually open the discharge valve and allow the pump to run
in continuous operation. Check the voltage, current and discharge pressure to make sure they are within allowable limits.
5. If voltage, current and discharge pressure are acceptable, you may continue to operate the pump on a continuous
basis. Please refer to “Troubleshooting” section of the manual or contact your local EBARA distributor if one of these
items is outside of allowable limits.
6. Do not allow the motor to start more than 20 times per hour.
Operation
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DMLU
Maintenance
Project: Model: Chk’d: Date:
Note: Disassembly and repair of the pump should only be performed by factory trained service centers. Errors made
by unqualified personnel can result in improper assembly and operation, therefore resulting in possible injury.
1. Recommended daily inspections:
a.) Check the motor current and its fluctuation. If there is a great deal of fluctuation, something may be clogging the
pump.
b.) Check to make sure the pump is providing the correct amount of flow. If the discharge decreases dramatically,
something may be clogging the pump.
2. Recommended monthly inspections:
a.) Measure the insulation resistance. The value should be more than 1 meg-ohm. If the resistance falls rapidly
even with an initial reading of more than 1 meg-ohm, further inspection and possible repair may be required.
3. Recommended annual inspections:
a.) Check the oil in the seal chamber. If the oil has turned white it is an indication that water has mixed with the oil
and the mechanical seal needs to be replaced. The service life of the mechanical seal can be prolonged by
replacing the oil in the seal chamber on an annual basis. See the recommended amount of oil below in Figure 5.
Replace the oil by laying the pump on its side as illustrated in Figure 6.
Figure 5
Figure 6
4. Extended storage:
a.) Keep pump in a dry environment, out of direct sunlight.
b.) Every 30 days, check the insulation resistance and rotate the impeller by hand to prevent rotating parts from
seizing together.
Always turn the power OFF before inspecting and repair the pump. Failure to do so can result in serious injury.
Warning
Motor Size (HP) 3 5 7.5 10 15 20 30
Mechanical seal
(mm) 30 40 45
Lubricating oil (oz)
Turbine oil ISO VG32 38 58 102
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DMLU
Troubleshooting
Project: Model: Chk’d: Date:
Trouble
Motor won’t turn.
Starts, but immediately
stops.
Operates, but stops after
a while.Thermal protector
is activated.
Does not pump.
Inadequate volume.
Overcurrent
Pump vibrates;
excessive noise during
operation.
Cause
(1) Foreign matter hinders level control float from functioning
properly.
(2) Power failure.
(3) Large voltage unbalance.
(4) Significant drop in voltage
(5) There is an open phase
(6) Faulty circuit connection
(7) Blown fuse
(8) Faulty starter
(9) Defective float
(10) Malfunctioning circuit breaker
(11) Foreign matter clogging pump
(12) Motor is shorted out
(13) Motor bearings are frozen
(1) Prolonged dry operation has activated motor protector
and caused pump to stop
(2) High liquid temperature has activated motor protector
and caused pump to stop
(1) Reverse rotation
(2) Valve is closed or partially clogged.
(3) Significant drop in voltage
(4) Discharge head is too high
(5) Large piping loss
(6) Low water level during operation causes vortexing (air
suction)
(7) Leak in discharge piping
(8) Clog in discharge piping
(9) Foreign matter clogging pump
(10) Worn impeller
(1) Large discrepancy between power source and voltage
(2) Significant voltage drop
(3) There is an open phase
(4) Reverse rotation
(5) Low head; pumping too much liquid
(6) Foreign matter clogging pump
(7) Motor bearing is worn or damaged
(1) Reverse rotation
(2) Pump clogged with foreign matter
(3) Piping vibrates
Remedy
(1) Remove foreign matter
(2 - 3) Contact electric power company for remedy
(4) Check power supply
(5) Check power supply; Inspect starter and connections
(6) Correct wiring
(7) Replace with correct size fuse
(8) Replace with correct starter
(9) Repair or replace float
(10) Repair location of circuit
(11) Remove clog from pump
(12) Repair or replace
(13) Repair or replace
(1) Raise the off float level
(2) Lower liquid temperature
(1) Correct rotation
(2) Open valve
(3) Check power supply
(4) Recalculate and adjust
(5) Recalculate and adjust
(6) Raise water level or lower pump
(7) Inspect, repair
(8) Remove foreign matter
(9) Remove foreign matter
(10) Replace impeller
(1) Contact power company for remedy
(2) Contact power company for remedy
(3) Check power supply
Inspect starter & electrical connections
(4) Check rotation
(5) Adjust discharge valve to desired flow
(6) Remove clog from the pump
(7) Repair or replace
(1) Correct rotation
(2) Remove clog from pump
(3) Install support for discharge piping
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DMLU
Disassembly and Reassembly
Project: Model: Chk’d: Date:
1. Disassembly:
a.) Unscrew and remove the bolts (120-2), and lift the motor out of the pump casing. Lay it down on its side carefully.
b.) Unscrew and remove the impeller bolt (275), then pull the impeller (021) off the motor shaft.
c.) Unscrew and remove the oil plug (193) and drain oil from seal chamber.
d.) Unscrew and remove the bolts (120-1), and remove the mechanical seal cover (016) carefully. Take care as there
may be oil remaining in the seal chamber.
d.) Remove the mechanical seal carefully to keep from damaging the seal faces.
2. Reassembly:
a.) Perform the above instructions in reverse order, replacing the o-ring, seal washer and gasket.
Note 1: After reassembly to the point of installing impeller on the shaft, turn the impeller by hand to make sure that it
rotates smoothly.
Note 2: It is recommended to use a screw adhesive (LOCKTITE 271) on the impeller bolt (275) during reassembly.
Note 3: After installing casing back onto pump, turn the impeller by hand through the pump suction to make sure that it
rotates smoothly without rubbing against the wear ring.
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DMLU
Sectional view
Project: Model: Chk’d: Date:
80DML62.2
PA R T
NO.
001
016
021
080
107
111
174
193
211
275
801
802
PART NAME
CASING
MECHANICAL SEAL COVER
IMPELLER
BUSHING
WEAR RING
MECHANICAL SEAL
DISCHARGE PIPE
OIL PLUG
AIRVENT VALVE
IMPELLER BOLT
ROTOR
S TATO R
MATERIAL
CAST IRON
CAST IRON
CAST IRON
STAINLESS
STEEL
BRONZE
—
CAST IRON
RUBBER (NBR)
BRASS
STAINLESS STEEL
—
—
NO. FOR
1 UNIT
1
1
1
1
1
1
1 SET
1 SET
1
1
1
1
PA R T
NO.
811
814
816
817
830
849-1
849-2
876
904
907
PART NAME
SUBMERSIBLE CABLE
MOTOR FRAME
POWER SIDE BRACKET
OPPOSITE SIDE BRACKET
SHAFT
BALL BEARING
BALL BEARING
AUTO CUT
LIFTING HANGER
BEARING COVER
MATERIAL
—
CAST IRON
CAST IRON
CAST IRON
STAINLESS STEEL
—
—
—
STEEL
STEEL
NO. FOR 1
UNIT
2
1
1
1
1
1
1
3
1
1
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DMLU
Sectional view
Project: Model: Chk’d: Date:
5 to 10 HP
80DML
100DML
150DML
PA R T
NO.
001
016
021
080
107
111
174
193
211
275
801
802
PART NAME
CASING
MECHANICAL SEAL COVER
IMPELLER
BUSHING
WEARING RING
MECHANICAL SEAL
DISCHARGE PIPE
OIL PLUG
AIRVENT VALVE
IMPELLER BOLT
ROTOR
STATOR
MATERIAL
CAST IRON
CAST IRON
CAST IRON
STEEL
BRONZE
—
CAST IRON
RUBBER (NBR)
BRASS
STAINLESS STEEL
—
—
NO. FOR
1 UNIT
1
1
1
1
1
1
1
1 SET
1
1
1
1
PA R T
NO.
811-1
811-2
814
816
817
830
849-1
849-2
856
904
907
PART NAME
SUBMERSIBLE CABLE (POWER)
SUBMERSIBLE CABLE (SIGNAL)
MOTOR FRAME
POWER SIDE BRACKET
OPPOSITE SIDE BRACKET
SHAFT
BALL BEARING
BALL BEARING
THERMAL PROTECTOR
LIFTING HANGER
BEARING COVER
MATERIAL
—
—
CAST IRON
CAST IRON
CAST IRON
STAINLESS STEEL
—
—
—
STEEL
STEEL
NO. FOR
1 UNIT
2
1
1
1
1
1
1
1
3
1
1
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DMLU
Sectional view
Project: Model: Chk’d: Date:
15 to 30HP
80DML
100DML
150DML
PA R T
NO.
001
016
021
080
107
111
174
193
211
275
801
802
PART NAME
CASING
MECHANICAL SEAL COVER
IMPELLER
BUSHING
WEARING RING
MECHANICAL SEAL
DISCHARGE PIPE
OIL PLUG
AIRVENT VALVE
IMPELLER BOLT
ROTOR
STATOR
MATERIAL
CAST IRON
CAST IRON
CAST IRON
STEEL
BRONZE
—
CAST IRON
RUBBER (NBR)
BRASS
STAINLESS STEEL
—
—
NO. FOR 1
UNIT
1
1
1
1
1
1
1
1 SET
1
1
1
1
PA R T
NO.
811-1
811-2
814
816
817
830
849-1
849-2
856
904
907
PART NAME
SUBMERSIBLE CABLE (POWER)
SUBMERSIBLE CABLE (SIGNAL)
MOTOR FRAME
POWER SIDE BRACKET
OPPOSITE SIDE BRACKET
SHAFT
BALL BEARING
BALL BEARING
THERMAL PROTECTOR
LIFTING HANGER
BEARING COVER
MATERIAL
—
—
CAST IRON
CAST IRON
CAST IRON
STAINLESS STEEL
—
—
—
STEEL
STEEL
NO. FOR 1
UNIT
2
1
1
1
1
1
1
1
3
1
1
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DMLU
Warranty
: Model: Chk’d: Date:
EBARA INTERNATIONAL CORPORATION
ROCK HILL, SOUTH CAROLINA
COMMERCIAL PUMP/ PRODUCTS LIMITED WARRANTY
(EXCEPT MODEL EPPD SUMP PUMPS)
Ebara International Corporation, Rock Hill, SC (“EIC-RH”) warrants to the original purchaser only (“Customer”) that the
EIC-RH Commercial Pump/Product (“Pump”) will be free of defects in workmanship and material for a period of twelve (12)
months from the date of installation or eighteen (18) months from the date of shipment by EIC-RH, whichever comes first,
provided that notification of any such defect is promptly given in writing to EIC-RH. Customer may be required at EIC-RH’s
request to verify that it is the Customer of the Pump and that the Pump was installed and operated in accordance with
EIC-RH’s instructions.
EIC-RH’s sole obligation under this warranty will be to repair or replace with a new or reconditioned Pump, such Pump as
has failed or has been found to be defective during the warranty period, or at EIC-RH’s sole option, to refund to the customer
an equitable part of the purchase price. In no event shall EIC-RH’s cost responsibility exceed the initial purchase price paid
by the Customer for the Pump.
EIC-RH shall be liable only for the cost of the Pump, or the cost of repair or replacement of any defective Pump. Customer
shall be responsible for labor, cost of removal and installation at Customer’s premises, transportation and insurance costs to
EIC-RH and any other incidental costs.
This warranty is void and does not apply if pump control cable is not properly connected to control panel, if damage is
caused by improper installation, improper maintenance, accident, alteration, abuse, misuse or if the Pump has been
disassembled prior to warranty evaluation without written authorization from EIC-RH.
Warranty service and information for return procedures will be provided by EIC-RH upon receipt of written notice describing
the defect or problem to:
Ebara International Corporation
Warranty/Claims
1651 Cedar Line Drive
Rock Hill, SC 29730
803-327-5005 Phone
803-327-5097 Fax
THE FOREGOING WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY ON THIS PUMP, AND ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, ARE DISCLAIMED AND EXCLUDED FROM THE TERMS OF THIS WARRANTY. EIC-RH’S
SOLE OBLIGATION IN CASE OF ANY DEFECT WILL BE TO PROVIDE THE WARRANTY SERVICE SPECIFIED ABOVE.
THE FOREGOING IS CUSTOMER’S SOLE AND EXCLUSIVE REMEDY, WHETHER IN CONTRACT, TORT OR OTHERWISE
AND EIC-RH SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND
WHATSOEVER.
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