EBARA DSC4 Series Operating and maintenance manual

Submersible Wastewater, Sewage Pump
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 
INSTRUCTION MANUAL P.1
PM32U 
1. Preface
Design of this EBARA pump is based on superior engineering and long experience.
To prevent trouble and provide satisfactory operation and long life, it is important to
understand the EBARA pump thoroughly by careful study of this manual. If any
questions arise regarding this manual, please direct them to EBARA. Your questions
will be promptly answered and your suggestion may be considered for incorporation
into our future products.
CAUTION : THIS INSTRUCTION MANUAL INCLUDES NECESSARY ITEMS
FOR INSTALLATION, OPERATION AND MAINTENANCE. READ THIS MANUAL
CAREFULLY TO ENSURE CORRECT INSTALLATION, OPERATION AND
MAINTENANCE.
BE SURE TO KEEP THIS INSTRUCTION MANUAL ON HAND FOR FUTURE
REFERENCE.
Safety Labels
Four different types of safety labels are used in this manual. Please study the labels
carefully so that the meaning of any safety warning you encounter is immediately
clear.
DANGER :indicates a potentially hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING :indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury
CAUTION :indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury or possible damage to the
equipment or machine.
Note : is used to call attention or to emphasize essential information.
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INSTRUCTION MANUAL P.2
PM32U 
2. Acceptance Inspection
Upon arrival of the pump –
(1) Check the nameplate information for agreement with specifications in respect
to model identification, head, pumping capacity, speed, output, voltage and
frequency.
(2) Check the pump has not been damaged during shipment and all plugs and
fastening bolts properly tightened.
(3) Check accessories and spare parts against the packing list.
If any problem is found, contact your dealer.
3. Installation
3.1 Foundation
Place concrete to build up the floor and discharge elbow foundations to the values
shown in installation drawing. The discharge elbow foundation must have sufficient
size and strength to support the weight of the pump body, submersible motor and
accessories plugs the weights of the discharge pipe, and to absorb vibrations and
impacts resulting from operation. Usually, it should weigh more than seven times the
pump weight.
3.2 Floor Frame (Fig. 1, 2 and 3)
Install a cable lead-out elbow and a floor frame on the floor over the pump pit. Attach
a guide pipe holder securely to the floor frame with bolts. As the guide pipe must be
installed vertically (with a tolerance of 1mm (0.04in) or less per 1m (3.3ft)), carefully
check the positional relationship between the floor frame location and the discharge
elbow foundation. (See Fig. 1 ∗)
*
Cable lead-out elbow
Fig. 1

 
INSTRUCTION MANUAL P.3
PM32U 
If the guide pipe holder is attached directly to the concrete, use hole-in anchor bolt as
shown in Fig. 3.
Fig. 2 Fig. 3
CAUTION : IF THE CABLE LEAD-OUT ELBOW IS TOO SMALL IN DIAMETER,
THE CABLE MAY BE HEATED WHERE IT RUNS THROUGH THE ELBOW.
3.3 Discharge Elbow Installation (Fig. 4)
WARNING : WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR
HOIST) AND LIFT SYSTEM.
CHECK POSITION AND TIGHTNESS OF LIFT SYSTEM SO THAT WEIGHT OF
THE PUMP IS NOT UNBALANCED.
FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS
ACCIDENTS.
Install the discharge elbow level on the bottom on the pump pit, and connect the
guide pipe.
!
!
Hole-in anchor bolt

 
INSTRUCTION MANUAL P.4
PM32U 
Fig 4
Support the guide pipe with bushings on discharge elbow and the guide pipe holder.
If the guide pipe requires a length exceeding 5.5m (18ft), an extension or
intermediate support may become necessary, in which case we are available for
consultation. When installing the discharge elbow, the guide pipe must be vertical
(with a tolerance of 1mm (0.04in) or less per 1m (3.3ft)), using a plum bob. If it is not
vertical, it may become impossible to lift pump. Discharge elbow level should be
within 0.1mm (0.04in) per 1m (3.3ft), both in the “X”and “Y”directions shown in Fig.
4. It is recommended practice that pipe installation be carried out with the discharge
elbow covered to protect against entry of concrete and mortar during the work.
CAUTION : FIX THE ANCHOR BOLTS TIGHTLY BY, FOR EXAMPLE, BY
WELDING THEM TO THE REINFORCEMENT BAR, ETC.
3.4 Discharge Pipe Installation (Fig. 5)
When mortar under discharge elbow has been sufficiently set, proceed with piping to
the discharge side.
CAUTION : DURING THIS WORK, TAKE CARE NOT TO SUBJECT THE
DISCHARGE ELBOW TO EXCESSIVE WEIGHTS.
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 
INSTRUCTION MANUAL P.5
PM32U 
Fig. 5
3.5 Water Level Switch Installation (Fig. 6)
Install a water level switches for use during automatic operation. If a float type switch
is used, each pump will required a total of 3 (or 4) for starting, stopping, (low level
alarm) and high-level alarm.
Above low limit level
Fig. 6

 
INSTRUCTION MANUAL P.6
PM32U 
3.6 Check the Followings Points (1) through (6) Prior to Pump Installation
(1) Ensure that the mechanical seal chamber is filled with specified amount of oil.
*ICS opt.
Ensure that the coolant chamber is filled with specified amount of coolant.
(2) All plugs and fastening bolts are properly tightened.
(3) The sealing chamber is not leaking.
(4) The pump is not damage and the cable glands and cables are in satisfactory
condition.
(5) Insulation resistance values are within limits. (See 3.6.2)
(6) Other points that require particular attention. (See 3.6.3)
3.6.1 Oil Supply (Fig. 7, 8 and 9)
Mech. Air vent.
Mech. Oil port
Mech. Air vent.
Mech. Oil port
Fig. 7 Fig. 8
The motor shaft is sealed with a tandem mechanical seal. The seal chamber provide
between the two sealing stages can be filled with turbine oil by standing the pump
vertically and unplugging “oil port”and “air vent”.
CAUTION : THE SEAL CHAMBER MAY BE UNDER PRESSURE. HOLD A
RAG OVER THE OIL PLUG TO PREVENT SPLATTER.
!

 
INSTRUCTION MANUAL P.7
PM32U 
Pour the specified oil into the sealing chamber through the “oil port”until the oil flows
out of the “air vent”. (See Table 1)
After the sealing chamber is filled to the specified level, put a sheet gasket between
the plug and the boss, and tighten the plug.
Floor surface
Oil funnel
Turbine Oil ISOVG32
Fig. 9
Use one of the following oils or
equivalent.
Shell : Turbo oil T32
Mobil : Mobil DTE oil light
Esso : Esso Tresso 32
Exxon : Teresstic 32
Gulf : Harmony 32, Crest 32
Caltex : Rega Oil R&O 32

 
INSTRUCTION MANUAL P.8
PM32U 
Table 1
Pump
Model
Model
Code
Approx.
Oil Capacity
(liter)
Pump
Model
Model
Code
Approx.
Oil Capacity
(liter)
150DSC4
AC-46050
AO-46050
2.4
300DSC4
FC-66050
FO-66050
2.4
AC-46060
AO-46060
FC-66060
FO-66060
AC-46075
AO-46075
GC-66075
GO-66075
2.3
BC-46100
3.1
EEC-66175
5.2
BC-46120
2.4
EEC-66200
CC-46120
3.2
EEC-66215
CC-46145
EEC-66245
CC-46175
400DSC4
D1C-106050
4.5
HC-46050
HO-46050
3.2
D1C-106060
D1C-106075
HC-46060
HO-46060
500DSC4
D2C-1060100
5.5
G1C-1060120
6.2
HC-46075
HO-46075
G1C-1060145
G2C-860175
C1C-46175
4.3
G2C-860200
C1C-46200
G2C-860215
C1C-46215
G2C-860245
C1C-46245
250DSC4
EC-66100
EO-66100
3.9
EC-66120
EO-66120
EC-66145
EO-66145

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INSTRUCTION MANUAL P.9
PM32U 
3.6.1 Coolant Supply (Fig. 7c, 8c and 9c)
Mech. Air vent.
Mech. Oil port
Mech. Air vent.
Mech. Oil port
Fig. 7c Fig. 8c
The motor shaft is sealed with a mechanical seal. The coolant chamber provided
between the two sealing stages can be filled with coolant by standing the pump
vertically and unplugging “Coolant supply hole”and “Air vent & full level check hole”.
CAUTION : THE SEAL CHAMBER MAY BE UNDER PRESSURE. HOLD A
RAG OVER THE PLUG TO PREVENT SPLATTER.
Pour the specified coolant into the coolant chamber through “Coolant supply hole”
until the coolant flows out of “Air vent & full level check hole”. (See Table 1c)
After the coolant chamber is filled to the specified level, plug the two holes.
Coolant supply hole
Air vent & full level check
hole
!
*ICS opt.

 
INSTRUCTION MANUAL P.10
PM32U 
Floor surface
Oil funnel
Turbine Oil ISOVG32
Fig. 9c
Table 1c
Pump
Model
Model
Code
Approx.
Coolant
Capacity
(liter)
Pump
Model
Model
Code
Approx.
Coolant
Capacity
(liter)
150DSC4C
AC-46050
AO-46050
51
250DSC4C
EC-66100
EO-66100
69
AC-46060
AO-46060
57
EC-66120
EO-66120
73
AC-46075
AO-46075
60
EC-66145
EO-66145
80
BC-46100
66
300DSC4C
FC-66050
FO-66050
57
BC-46120
60
CC-46120
60
FC-66060
FO-66060
60
CC-46145
68
HC-46050
HO-46050
52
GC-66075
GO-66075
60
HC-46060
HO-46060
58
HC-46075
HO-46075
61
The ingredients of the coolant are
to be as follows.
30% : Propylene glycol
70% : Water
Coolant

 
INSTRUCTION MANUAL P.11
PM32U 
3.6.2 Insulation Resistance Measurement
WARNING : ALL ELECTRIC WORK SHOULD BE PERFORMED BY A
QUALIFIED ELECTRICIAN AND ALL NATIONAL AND LOCAL ELECTRICAL
CODES MUST BE OBSERVED.
Although insulation resistance of this pump has been shop tested, it should be
rechecked prior to installation, using the following procedure. Usually, insulation
resistance of a minimum of 50MΩis considered satisfactory (when measured with a
DC 500V Megger).
Measurement procedure (Refer to Figs. 10 and 11)
Connect the minus (-) terminal to G of the DC 500V Megger to the G terminal of the
power cable, or a motor bolt.
In dual power cable, connect the L4-, L5- and L6- phases electrically and keep them
off the ground.
Touch the plus (+) terminal of the Megger to L1-phase (or L2-phase or L3-phase) of
the power cable, and read the insulation resistance.
Touch the plus (+) terminal of the Megger to P1 (or P2) and P3 (or P4) of the
protective device cable, with the minus (-) terminal G connected as above, and read
the insulation resistance.
CAUTION : DO NOT CONNECT THE TWO MEGGER TERMINALS BETWEEN
P1 AND P2 OR P3 AND P4, TO AVOID DAMAGE TO THE PROTECTIVE DEVICE.
KEEP THE CABLES OFF THE GROUND WHILE TAKING ALL MEASUREMENTS.
Fig. 10
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!

 
INSTRUCTION MANUAL P.12
PM32U 
*Single Power Cable (50HP –175HP models)
P1 P2
G
L3
L1
L2
Power cable Motor
P3 P4 G
Protective device cable
*Dual Power Cable (200HP - 245HP models)
Fig. 11

 
INSTRUCTION MANUAL P.13
PM32U 
3.6.3 Other Checks Requiring Particular Attention
(1) Minimum operating water level
Be sure that the pump stop level is not lower than the minimum operating
water level specified in the technical document. If the stop level is lower, a
vortex flow can occur causing the pump to intake air, resulting in noise and
vibration.
If there is possibility that the minimum water level may decrease to an
excessive extent, it is necessary to use a minimum water level may decrease
to an excessive extent; it is necessary to use a minimum water level alarm. An
alternative measure would be a water level-dependent automatic control
system where the motor is turned off to automatically stop the pump with the
water lowered to a critical level and is turned on again to resume automatic
operation when water is restores to a safe level.
(2) Pump location relative to pump pit water inlet
If the pump is installed near the pump pit water inlet, it can be considerably
disturbed; it can be shaken and the cables whipped by vigorous inlet water,
resulting in damage. Therefore, the pump should be located as far from the
water inlet as possible.
(3) Size of debris
Entry of large or long debris can result in a blocked impeller.
If such problem actually occurs, the pump can be readily lifted out and
disassembled for servicing, which is however, time and labor consuming.
The primary consideration therefore should be to prevent the ingress of any
oversized objects into the sump by use of a screen, etc. Another important
consideration is to minimize presence of abrasive substances, such as sand, in
the liquid.
If the contents of such substances becomes high, the impeller is increasingly
worn, leading to the degradation of capacity.
Note : In case any problem as above actually takes place, contact us
immediately.

 
INSTRUCTION MANUAL P.14
PM32U 
3.7 Pump Installation (Fig. 12)
WARNING : WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR
HOIST) AND LIFT SYSTEM.
CHECK POSITION AND TIGHTNESS OF LIFT SYSTEM SO THAT WEIGHT OF
THE PUMP IS NOT UNBALANCED.
FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS
ACCIDENTES.
After the pump has been thoroughly checked to verify that it is in order, lift the pump
body and fit the sliding guide of the pump body to the guide pipe. Then, lower the
pump body slowly along the pump guide.
The pump is automatically connected to the discharge elbow.
If the pump cannot be slid down smoothly, the guide pipe may not be vertical or the
lifting method may be wrong. Check these points to determine the cause for
correction.
After the pump is installed attach the chain to the hook of the floor frame.
GUIDE PIPE
CHAIN HOOK
DISCHARGE ELBOW
SLIDING GUIDE
Fig. 12
When the pump is installed indoors, it should be a good idea for convenience’s sake
that a hoist, for example, be provide on the ceiling so that it can be moved to the
pump lifting center when necessary.
!

 
INSTRUCTION MANUAL P.15
PM32U 
3.8 Cable Installation (Fig. 13)
When the pump has been installed, pull out the power cable, protective device cable,
water level switch cable, etc. from the cable lead-out elbow on the floor and connect
them to the control panel.
FLOOR PLATE
CABLE LEAD-OUT ELBOW
Fig. 13
CAUTION : HANDLE THE CABLES VERY CAREFULLY. IF THEY ARE BENT
OR PULLED EXCESSIVELY, THE CABLE AND THE MOLDED SEAL MAY BE
DAMAGED, RESULTING IN INSULATION FAILURE.
ALSO, CARE IS NEED TO PROTECT CABLE ENDS AGAINST WATER
INTRUSION.
Note : The cables should be cut to the necessary length.
If the cable is too short, it can prevent lifting of the pump.
If the cable is too long and laid loose on the pump pit bottom, it could be sucked into
the pump.
If left coiled on the ground, it could be locally heated.
3.9 Floor Plate
Finally, install the floor plate over the pump pit, and the installation work is finished.
!

 
INSTRUCTION MANUAL P.16
PM32U 
4. Electric Wiring
4.1 Power Cable Connection
WARNING : CHECK THAT THE POWER IS LOCKED OFF AND
DISCONNECTED BEFORE WORKING ON PUMP.
The electric wiring for a submersible motor is no different from that of an ordinary
motor, except that the direction of rotation cannot be easily verified.
Wiring to wrong terminals results in a reversed motor, and to prevent this and to
achieve best results, the following wiring procedure is recommended.
Connect terminals L1, L2, and L3 (and L4, L5 and L6 in dual power cable) to the
secondary terminals L1, L2 and L3 (and L4, L5 and L6 in dual power cable) of the
electromagnetic switch or breaker respectively. Connect the remaining terminal G to
ground.
WARNING : WHEN PREPARING POWER CABLE LEADS FOR CONNECTION
TO CONTROL, IT IS ESSENTIAL THAT THE GROUND LEAD BE LONGER THAN
THE POWER LEADS. THE GROUND LEAD MUST HAVE AT LEAST 2 ” (50 MM)
SLACK REMAINING AFTER CONNECTION, WHEN SPACE PERMITS. THIS IS
DONE FOR ELECTRICAL SAFETY. IF THE CABLES IS MISTAKENLY PULLED
OUT, THE GROUND LEAD WILL BE THE LAST WIRE BROKEN.
4.2 Grounding (Fig. 14 and Table 2)
Be sure to connect the ground line (labeled “G”) to ground. Prior to grounding, ensure
that the wire is the specified one (labeled “G”).
Also, verify that grounding continuity has been established inside the motor by
checking that ground wire (labeled “G”) is electrically conductive with the bolt on the
top of the motor (to be stripped of paint).
Ground the motor according to local codes.
!
!

 
INSTRUCTION MANUAL P.17
PM32U 
Ground terminal
Ground wire
Ground
plate
G.L
Fig. 14
Table 2 (Example)
Motor
classification
Grounding
resistance
Grounding line
diameter
AC 600V below
10Ω
φ 1.6 mm
(Source : Electrical Equipment Technical Standards, Ministry of International Trade
and Industry).
4.3 Protective Device Cable Connection (Fig. 15 and Table 3)
This pump have a leakage detector at the motor bottom and a thermal protector, in
the stator coil to protect the motor, with cable connections as illustrated in Fig. 15.
Connect terminals P1 and P2 for the thermal detector to P1 and P2 of the same
control connector. Connect the remaining terminal G to ground. Table 3 shows
detailed specifications regarding protective devices.
For ground G
For thermal
protector P1
P2
For leakage detector
P4
P3
SOOW-A x #14x5 CORE
Fig. 15

 
INSTRUCTION MANUAL P.18
PM32U 
Table 3
Thermal protector
Leakage detector
Type
9700K 06-215
OLV –5 (float type)
Manufacturer
SENSATA TECHNOLOGIES
JAPAN LTD.
NOHKEN INC.
Contact rating
AC 115V/230V18A/12A (max)
AC 300V0.5A (max)
Contact type
B-contact (normally closed)
B-contact (normally closed)
Cable terminal
identification
P1
P2
P3
P4
Material and size of
cable
SOOW-A#14
WARNING : AN EARTH LEAKAGE BREAKER MUST BE USED ACCORDING
TO LAW TO PREVENT ELECTRICAL ACCIDENTS.
CAUTION : A MOTOR PROTECTIVE DEVICE SHOULD BE INSTALLED ON
CONTROL PANEL TO PROTECT THE SUBMERSIBLE MOTOR AGAINST
OPEN-PHASE, OVER-CURRENT OR INCHING.
4.4 Water Level Switch Cable Connection (Fig. 16 and 17)
Figs. 16 and 17 illustrate typical float switch applications for water level control.
Three (or four) float switches are required for single unit operation, whereas four (or
five) are necessary for two-unit alternating operation.
If you desire our Ebara Water Level Control Float Switch, ask us for a catalog.
Alarm (abnormal low level)
OFF
ON
Alarm (abnormal high level)
Fig. 16 Single Unit Operation
!
!

 
INSTRUCTION MANUAL P.19
PM32U 
OFF
Alarm (abnormal high level)
ON (2nd Unit)
ON (1st Unit)
Alarm (abnormal low level)
Fig. 17 Two-Unit Alternating Operation
5. Operation
5.1 Operational Limitations
This pump is designed to operate under the following conditions:
(1) Liquid temperature : max. 40ºC (104F）
(2) Liquid : This pump must not be used with sea water and corrosive chemicals
or combustible liquids.
(3) Lowest liquid level : Refer to lowest liquid level shown in the technical
document.
(4) Voltage variations : The motor is designed to supply its rated output at
variations of up to10% of the rated voltage at the rated frequency.
(5) Voltage balance : Balance among the supply phases should not exceed
deviations in excess of1%.
(6) Frequency variations : The motor is designed do supply its rated output at
variations of up to +3%／-5% of the rated frequency at the rated voltage.
(7) Frequency of starts : The pump should not be started in excess of 15
times per hour for 4 pole and 6 pole 50hp to 145hp, 10 times per hour for 4
pole, 6 pole and 8 pole 175hp to 245hp and 10 pole 50hp to 145hp.