Ebsray R SERIES Guide

Publication # 1852-04 EN
EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
R SERIES
MODEL RX10
…. For Submersible
LPG APPLICATIONS
(50Hz & 60Hz)

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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 RX10 SUBMERSIBLE LPG PUMPING SYSTEM..................................................................5
2.2 EBSRAY RX10 SUBMERSIBLE PUMPSET..........................................................................................5
2.3 "THREE-TIER" PROTECTION SYSTEM...............................................................................................5
2.4 PPVVALVE (POSITIVE PRESSURE VENTILATION VALVE)...........................................................6
2.5 BYPASS VALVE - EBSRAY MODEL RV18 NRV..................................................................................6
2.6 DIFFERENTIAL PRESSURE SWITCH..................................................................................................6
2.7 CONTROL CONSOLE............................................................................................................................6
2.8 EBSRAY LPG SYSTEM CONTROLLER...............................................................................................6
2.9 LIST OF SYSTEM COMPONENTS .......................................................................................................6
a) COMPONENTS SUPPLIED BY EBSRAY ........................................................................................6
b) COMPONENTS SUPPLIED BY OTHERS.........................................................................................7
SECTION 3 - INSTALLATION .......................................................................................................................................8
3.1 LOCATION..............................................................................................................................................8
3.2 PUMPSET INSTALLATION....................................................................................................................8
3.3 PORT ALIGNMENT................................................................................................................................8
3.4 DISCHARGE RISER...............................................................................................................................8
3.5 ELECTRICAL CONDUIT ........................................................................................................................9
3.6 PUMP AND SYSTEM PIPING CONNECTIONS ...................................................................................9
3.7 RECOMMENDED ORDER OF ASSEMBLY..........................................................................................9
3.8 LPG/PRODUCT DISCHARGE PIPE FITTINGS..................................................................................11
3.9 DIFFERENTIAL PRESSURE SWITCH................................................................................................11
3.10 BYPASS VALVE...................................................................................................................................11
3.11 PPVVALVE ......................................................................................................................................12
3.12 LEAK CHECK .......................................................................................................................................12
3.13 ELECTRICAL CONNECTIONS - PUMPSET AND SYSTEM..............................................................12
3.14 JUNCTION BOX ...................................................................................................................................12
3.15 DIFFERENTIAL PRESSURE SWITCH (DPS).....................................................................................13
3.16 CONNECTING CABLE.........................................................................................................................13
3.17 CONTROL CONSOLE..........................................................................................................................13
SECTION 4 - OPERATION ..........................................................................................................................................14
4.1 DESCRIPTION......................................................................................................................................14
4.2 LUBRICATION......................................................................................................................................14
4.3 PRE-STARTUP CHECKLIST...............................................................................................................14
4.4 STARTUP PROCEDURE.....................................................................................................................14
SECTION 5 - CONTROL CONSOLE - DESCRIPTION, OPERATION & ADJUSTMENT.........................................16
5.1 OPERATIONAL FEATURES OF THE CONTROL CONSOLE - a) FASCIA......................................17
5.2 OPERATIONAL FEATURES OF THE CONTROL CONSOLE - b) INTERIOR .................................19
SECTION 6 - MAINTENANCE.....................................................................................................................................22
6.1 INSPECTION ........................................................................................................................................22
6.2 SERVICE...............................................................................................................................................22
6.3 SERVICE EXCHANGE.........................................................................................................................22
6.4 SPARE PARTS.....................................................................................................................................22
SECTION 7 - TROUBLE SHOOTING...................................................................................................................23 - 27
SECTION 8 - APPENDICES
APPENDIX A TYPICAL INSTALLATION P &ID
APPENDIX B RX10 OUTLINE DIMENSIONS AND SPECIFICATION
APPENDIX C TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAM
APPENDIX D PRE-STARTUP COMMISSIONING CHECKLIST
APPENDIX E INSPECTION LOG
APPENDIX F COPIES OF CERTIFICATIONS & DECLARATIONS FOR RX10 PUMP/MOTOR

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WARNING
EBSRAY PUMPS Pty. Ltd.
628 PITTWATER ROAD PHONE: (+61 2) (9905 0234)
BROOKVALE NSW 2100 AUSTRALIA FAX: (+61 2) (9938 3825)
www.ebsraypumps.com.au
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 RX10 - 3.7 kW
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 (eg. 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
Federal, State and Local Codes, Regulations and Standards.
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. CAUTION
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

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WARNING
WARNING
This publication is intended to assist those involved
with the installation, operation and maintenance of
EBSRAY Model RX10 Regenerative Turbine
Submersible Pumpset and the pumping system.
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 standards, directives,
codes and regulations is fully understood and
exercised in the installation, operation and
maintenance of EBSRAY RX10 pumpsets.
These instructions are intended to assist correct
pump installation, operation and maintenance
requirements. They are additional to, and do not
supersede or override any applicable statutory,
legal or regulatory requirements.
CAUTION Installation and servicing
of this equipment should be performed by qualified
competent personnel in accordance with relevant
directives, standards, codes, regulations 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.
Standard domestic packing is suitable for shipment in
covered transports. Pump ports must be sealed to
exclude ingress of condensation, moisture or foreign
material. When received on site the pump 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 chamber to protect
pumpset from the effects of condensation.
Never allow water or
any corrosive product to enter the pump, motor or
electrical conduit. This may damage the pumpset
and will void the warranty.
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.
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. All EBSRAY manufactured pumps and equipment
are warranted as standard for one (1) year against
faulty workmanship and/or materials. Refer RX10
exceptions below.
2. A two (2) year or 7,500 hours (whichever occurs
first) New Pump Warranty applies on RX10
Pumpsets when installed and operated in
conjunction with the Ebsray Control Console and in
strict accordance with the system design and
recommendations as set out in the current
EBSRAY I.O.&.M Data supplied with each
pumpset.
3. RX10 Pumpset Warranty is void if the pumpset is
installed and operated either without the EBSRAY
Control Console or PLC installed and connected.
4. To validate Warranty conditions, a completed copy
of the RX10 Inspection Run Log (Appendix E)
MUST be completed in full and returned to
EBSRAY. Failure to do so may void the Warranty.
5. Refer to EBSRAY or Factory Appointed
Representative for further details on the RX10
Pumpset Warranty conditions.
6. Ancillary equipment supplied by EBSRAY but
manufactured by others will be in accordance with
those manufacturer's written warranty conditions.
SECTION 1 - GENERAL
1.1 INTRODUCTION
1.2 TRANSPORTATION AND PACKING
1.3 RECEIVING INSPECTION
1.4 HANDLING
1.5 WARRANTY
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The system is designed around the RX10 Submersible
Pumpset which is a single stage Regenerative Turbine
Pump, close coupled to a 3.7 kW Submersible Electric
Motor (See Certifications APPENDIX F).
The combination of robust, specially designed, 'product
lubricated' bearings using EBSRAY's unique BCL
(Bearing Cooling and Lubrication system) and the
EBSRAY "Three-Tier" Protection System ensures
reliable operation over the intended periods between
routine maintenance overhauls.
The EBSRAY RX10 is designed as a 'fully serviceable'
pumpset.
Figure 1
EBSRAY BCL(Bearing Cooling and Lubrication
system)
In order to understand the operational and protection
system requirements of the RX10 pumpset, some
knowledge of the BCLsystem is required.
One of the key elements for optimal performance and
longevity of any submersible motor/pump is to cool and
lubricate the sleeve bearings. In order to cool and
lubricate effectively, the LPG must remain in the liquid
state at all times.As heat is absorbed by the LPG
during its circulating/lubricating cycle, any excessive
drop in pressure or increase in temperature would
cause it to 'flash off' into vapour. This would in turn
cause either a loss of lubrication and cooling or inject
vapour into the liquid being pumped. Both these
situations would be detrimental to pump service life and
performance.
A - B (see figure 2)
At all times during operation, cool LPG at pump
discharge pressure must be delivered through the
thrust bearing assembly, through the lower motor
bearing, through the gap between the stator and rotor
and also through the upper motor bearing.
B - C (see figure 2)
Directly above the upper motor bearing is a
temperature monitoring switch. From this area, LPG is
returned and cooled via a spiral tube, (within the cooler
pump discharge liquid) and finally returning into the
intermediate pressure area of the impeller.
Adequate differential pressure is critical to
maintain this internal flow and to maintain the
liquid state of the LPG.
Figure 2
The EBSRAY "Three-Tier" Protection System forms an
integral part of the pumping system. (Refer Warranty) It
ensures proper pumpset performance as outlined
previously. 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.
SECTION 2 – SYSTEM DESCRIPTION
2.1 EBSRAY RX10 SUBMERSIBLE
LPG PUMPING SYSTEM
2.2 EBSRAY RX10 SUBMERSIBLE
LPG PUMPSET
2.3 "THREE-TIER" PROTECTION SYSTEM

6
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 Control
Console for reset. Reset is protected by a keylock. i.e.
the fault can be isolated for 'controlled' assessment and
fault rectification prior to reset and re-start.
The PPVValve's low opening/closing pressure allows
equalisation of liquid level in the pump housing when
the pump 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.
The 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 RX10 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 pump is idle.
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 Differential Pressure Switch signals the Control
Console if the minimum system differential pressure:
a) Is not attained on startup after the preset time delay.
b) Falls below the predetermined pressure during
pumping/operation of the Pumpset.
The Control Console houses the control circuits which
provide the link between the power supply, the
Pumpset and the various sensing and monitoring
devices.
The Control Console also houses the "Three Tier"
protection system PLC indicators and the key protected
switches for control of Pumpset operation. In addition
to these Red fault indicators, the Control Console has a
Green indicator (C.C.) to indicate that the control circuit
is energised. An Hour Run meter is provided for
monitoring pumpset usage time. Access to the Control
Console internals is secured by a keyed locking door.
A complete LPG System controller C860101 is
available which combines all the functions of the
standard Control Console with added functions such as
Emergency Stop air switching, Voltage free contact for
dispenser control etc. (Refer EBSRAY for details)
a) COMPONENTS SUPPLIED BY EBSRAY (refer P & ID Appendix A for corresponding Item #)
ITEM # DESCRIPTION QTY
1. EBSRAY MODEL RX10 - 3.7 kW SUBMERSIBLE PUMPSET..........................................................1
2. EBSRAY 'THREE-TIER' PROTECTION PLC MOTOR CONTROL CONSOLE - IP55 # C860001...1
3. DIFFERENTIAL PRESSURE SWITCH (DPS) - ¼" (F)NPT PRESSURE PORTS
½" (M)NPT ELECTRICAL CONDUIT # C860202..............................................................................1
FOLLOWING ITEMS 4 & 5 ARE ALTERNATIVES.
ONLY ONE (ITEM 4 OR ITEM 5) IS REQUIRED FOR EACH INSTALLATION.
4. ELECTRICAL FITTING KIT # K860400 CONSISTING OF:
4A JUNCTION BOX - Ex d WITH 1 x ½" NPT and 3 x M25 CONDUIT ENTRIES,
8 x 2.5 mm TERMINALS and 2.5 mm GROUND TERMINAL # C860400..................................1
4B ¾" (F)NPT x.25(F)M CONDUIT SEAL - Ex d WITH COMPOUND # C860421...........................1
4C 25(M)M HEX NIPPLE - Ex d # C860460......................................................................................1
4D 25(M)M PLUG - Ex d # C860465 .................................................................................................1
4E ARMOURED CABLE BARRIER GLAND Ex d U # C860470......................................................1
5. ELECTRICAL FITTING KIT # K860403 CONSISTING OF:
5A JUNCTION BOX - Ex d WITH 8 x M25 CONDUIT ENTRIES,
12 x 2.5 mm TERMINALS AND 2.5 mm GROUND TERMINAL # C860401...............................1
5B ¾" (F)NPT x 25(F)M CONDUIT SEAL - Ex d WITH COMPOUND # C860421...........................1
5C ½" (F)NPT x 25(M)M ADAPTOR - Exd #C860451........................................................................1
5D 25(M)M HEX NIPPLE - Ex d # C860460......................................................................................1
5E 25(M)M PLUG - Ex d # C860465 .................................................................................................5
5F ARMOURED CABLE BARRIER GLAND Ex d U # C860470......................................................1
2.4 PPVVALVE
(POSITIVE PRESSURE VENTILATION VALVE)
2.5 BYPASS VALVE - EBSRAY MODEL RV18-NRV
2.6 DIFFERENTIAL PRESSURE SWITCH
2.7 CONTROL CONSOLE (EBSRAY # C860001)
2.8 EBSRAY LPG SYSTEM CONTROLLER
(EBSRAY # C860101)
2.9 LIST OF SYSYTEM COMPONENTS

7
FOLLOWING ITEMS 6 & 7 ARE ALTERNATIVES.
ONLY ONE (ITEM 6 OR ITEM 7) IS REQUIRED FOR EACH INSTALLATION.
6. ANGLED TUBE FITTING KIT # K850500 CONSISTING OF:
6A ¾" (M)NPT x ¾" TUBE CONNECTOR - SS # C850500..............................................................1
6B ¾" (M)NPT x ¾" MALE ELBOW - SS # C850520........................................................................1
6C 1" (M)NPT x ¾" TUBE CONNECTOR - SS BORED THROUGH # C850540.............................1
7. STRAIGHT TUBE FITTING KIT # K850501 CONSISTING OF:
7A ¾" (M)NPT x ¾" TUBE CONNECTOR - SS # C850500..............................................................2
7B 1" (M)NPT x ¾" TUBE CONNECTOR - SS BORED THROUGH # C850540.............................1
8. EBSRAY PPVVALVE INTERNAL MOUNTING KIT # K850001 CONSISTING OF:
(REFER TO ITEMS 30 - 33 FOR EXTERNAL PPV VALVE MOUNTING)
8A EBSRAY PPVVALVE (POSITIVE PRESSURE VENTILATION VALVE)
½" (F)NPT x ½" (F)NPT # C850001.............................................................................................1
8B ½" (M)NPT x 3/8" TUBE CONNECTOR - BRASS # C850510......................................................1
8C x
3/8" OD x 1.2mm WALL U-TUBE - COPPER # C850600..........................................................1
9. EBSRAY 'RV18 NRV' (NON RETURN VALVE) BYPASS VALVE FLANGED
25mm NB ANSI 300LB, 500 - 900 kPa (5 – 9 Bar) DIFFERENTIAL PRESSURE RANGE ..............1
11. 63mm, 0-2500 kPa (0 –25 Bar) PRESSURE GAUGE # C850400.....................................................2
b) COMPONENTS SUPPLIED BY OTHERS (Refer to P & I D Appendix A for corresponding Item #)
ITEM # DESCRIPTION QTY
12. 2" (M)NPT EXCESS FLOW VALVE REGO A3500L4 (OR EQUAL)..................................................1
13. 50 NB Sch' 80 PIPE (DISCHARGE RISER) THREADED 2" (M)NPT ON PUMP END
[LENGTH AS REQUIRED]..................................................................................................................1
14. 150 NB Sch'40 OR Sch'80 PIPE (PUMP HOUSING) [PART OF PRESSURE VESSEL].........1
15. 8 NB BALL VALVE ..............................................................................................................................1
16. VAPOUR BALANCE CLOSING MECHANISM WITH GLAND...........................................................1
17. PUMP INLET CLOSING MECHANISM WITH GLAND ......................................................................1
18. 8 NB VALVE ........................................................................................................................................4
19. 32 NB (MIN) Sch'40 PIPE (PUMP DISCHARGE) ..............................................................................1
20. ¼" OD x 0.9 WALL SS TUBING..........................................................................................................1
21. ¼" (M)NPT x ¼" TUBE CONNECTOR - SS........................................................................................4
22. ¾" OD x 1.6 WALL SS TUBING (ELECTRICAL CONDUIT) [LENGTH AS REQUIRED]..................1
23. 25 FULL BORE (MIN) PNEUMATIC ACTUATED BALL VALVE .......................................................2
24. 25 NB(MIN) EXCESS FLOW VALVE..................................................................................................1
25. 50 FULL BORE BALL VALVE.............................................................................................................1
26. 32 NB (MIN) SOFT SEATED IN-FLANGE BACK CHECK VALVE ....................................................1
27. 8-CORE PLUS GROUND x 2.5mm2(MIN) ARMOURED PVC COATED CABLE.............................1
28. 8 NB HYDROSTATIC RELIEF VALVES.............................................................................................3
29. FLANGE INSULATION GASKET KIT (SIZE AS REQUIRED) ...........................................................3
PARTS REQUIRED FOR ALTERNATIVE EXTERNAL PLACEMENT OF PPV

VALVE (Item 8A)
30. 8 NB INSULATING UNION .................................................................................................................1
31. 20 NB EXCESS FLOW VALVE...........................................................................................................2
32. 8 NB BALL VALVE ..............................................................................................................................2
33. 3/8" OD (MIN) X 1.2 WALL SS TUBING .............................................................................................1

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SECTION 3 - INSTALLATION
CAUTION
Installation and removal of this equipment should
be performed by qualified competent personnel in
accordance with relevant directives, standards,
codes, regulations 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.
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 150 NB (min) Sch'40 or Sch'80 pipe. 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 50mm
diameter. It is isolated from the tank with a remotely
operated 50mm (full bore) ball valve and an excess
flow valve designed for pump inlet (suction) duties. The
centre height of the inlet port must be 45mm (min)
above the bottom (inside) of the housing. (Refer P&ID
Appendix A)
Pump 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.
Accurate alignment of the pump inlet port with the
pump housing port is critical for efficient pump
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, electrical insulation
will be ineffective.
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 3. and Appendix B.
Figure 3
To determine overall length of riser (Refer to figure 4):
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 982 mm to allow for pumpset length (to
centre line of inlet port).
The result is the overall 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 32 mm NB (min) discharge
connection.
3.1 LOCATION
3.2 PUMPSET INSTALLATION
3.3 PORT ALIGNMENT
3.4 DISCHARGE RISER

9
To determine minimum overall length of conduit
(Refer to figure 4):
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. The result is the
minimum overall
conduit length
required (B).
Figure 4
CAUTION
Installation and removal of this equipment should
be performed by qualified competent personnel in
accordance with relevant directives, standards,
codes, regulations, and site restrictions in
conjunction with these instructions.
Refer to P&ID Appendix A for system arrangement and
relative positioning of components.
It is extremely important that no piping stresses be
transferred to the pump.
Two connections to pumpset are required for
installation:
1) The discharge pipe (riser)
2) The electrical conduit
The discharge port has a 2" NPT female thread and the
conduit port has a ¾" NPT female thread. Both NPT
threaded connections on pumpset require a thread
engagement as per NPT Standard. EBSRAY
recommend at least 8 full turns for correct installation
and sealing. (27 mm x 29 mm AF tube spanner is
required)
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.
Prior to fitting any wiring into conduits, all burrs
and sharp edges must be removed from conduit
ends.
Figure 5
NOTE
Conduit length should be accurately determined
prior to any installation. Cutting conduit with wires
installed is not recommended.
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.
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 6 & 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.
3.5 ELECTRICAL CONDUIT
3.6 PUMP AND SYSTEM PIPING CONNECTIONS
3.7 RECOMMENDED ORDER OF ASSEMBLY
WARNING
WARNING
WARNING

10
Figure 6
Figure 7
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 8
Figure 8
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 setscrews 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 242 or equal, fit the three set screws
in the top of the pumpset. Tighten setscrews
against discharge riser.
NOTE
These screws must be tight
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 pump 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.