Ebsray R SERIES Guide

Publication # 2402-10 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:
DANGE
R
1.
Non-compliance with requirements under this heading could create circumstances which may lead to
serious personal injury or death or substantial property damage.
WARNING
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.
CAUTION
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:

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
tory requirements.
Before starting any work
statutory, legal or regula
,
completely read/reviewe
(propane and
flammab em
ensure total complian
ing
be perf uit
hen the equipment supplied utilises components
The Pumpset must be
original sig
pressure, temperature, v
this Publication should be
d by all persons involved
with the work. If any part of this Publication is
unclear, obtain clarification before proceeding with
any work.
As LPG
butane) is regarded as a
e caution must be taken to
ce 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 s
le liquid, extr
ervic
of this equipment should
ably qualified competent
personnel in accordance with relevant Codes,
Regulations, Standards, Directives and site
restrictions, in conjunction with these
instructions.
ormed by s
W
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.
operated within the
n parameters of flow,
oltage 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.
selected de
1.2 TRANSPORTATION AND PACKING
Standard domestic packing is suitable for ship
covered transports. Pumpset ports must be sea
ment in
led 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
commissio
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.
ned immediately, special preservative
Never allow water or any
corrosive product to enter
e Pumpset, Motor or electrical conduit. This may
WARNING
th
d ge the Pumpset and will void the Warranty.ama
1.3 RECEIVING INSPECTION
SHORTAGES and/or DAMAGE: On receipt of
inst the dispatch
e. Any damage or
equipment, check all items aga
documents and inspect for damag
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.
DANGE
R
DANGE
R
1.4 HANDLING
Do not drop Pumpset! Care should be taken in
psets. A sling should be placed
mpset in order to minimise stress
damage may result if
moving/handling Pum
under or around a Pu
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
correct handling and due care is not taken.
CAUTION
No welding is to be
performed on any part of
piping, vapour returns,
conduits etc.) with set/wires installed. Failure
to observe this w
the sys ge
Pump
arning could result in severe
tem (dischar
WARNING
Motor and/or wiring damage and will void the
Warranty.
1.5 WARRANTY
1 All EBSRAY manufactured pumps and equipmen. t
ard for one (1) year against
ip and/or materials. Refer to
ut in the current
RX33 Pumpsets -
AY Pump Controller
Y PLC installed and
agreement of an
are warranted as stand
faulty workmansh
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:
WARNING
a) when installed and operated in strict
accordance with the system design and
recommendations as set o
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
all as per a) and b) above
4. RX33 Pumpset Warranty is voided if the Pumpset
is installed and operated:
a) without the EBSR
installed and connected, or
b) without the EBSRA
connected, or
c) without EBSRAY’s written
alternative method of Pumpset protection
4

5. To validate Warranty conditions, a completed copy Refer to EBSRAY or Appointed Representative for
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.
clarification or further details on the RX33 New or
Service Exchange Pumpset Warranty conditions.
SECTION 2 – SYSTEM DESCRIPTION
5
2.1 EBSRAY RX33 SUBMERSIBLE LPG
PUMPING SYSTEM
The sy nd the RX33 Submersiblestem is designed arou
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 BSRAY "Three-Tier" Protection System forE ms an
ion of the
2. tch) Operation of the
3. rLoad) Operation of the system
ic pumpset shutdown from any of the
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) Operat
system will be halted if fluid within the BCL™System
exceeds a preset temperature.
'DPS' (Differential Pressure Swi
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.
'MOL' (Motor Ove
will be halted if motor current exceeds a preset
maximum setting.
Following automat
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 PP osing pressure allowsV™Valve's low opening/cl
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
OTE: This publication is specific to the L861002
and associated control circuits that monitors and
controls the operation of the Pumpset. Pumping
System information is displayed on an LCD screen.
N
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.

SECTION 3 – INSTALLATION
al of this equipment should be performed by suitably qualified
fittings, flanges, etc. while under pressure (vapour pressure of
Installation and remov
CAUTION
competent personnel in accordance with relevant Codes, Regulations, Standards,
Directives and site restrictions - in conjunction with these instructions.
Never loosen or remove
DANGER
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 required configuration for your installation.
provides for either Coaxial or Parallel wiring
connections. Ensure that the supplied Pumpset has the
Reconfiguration of the wiring connection is possible by
authorised representatives of EBSRAY.
3.2 INITIAL INSTALLATION
6
3.2.1 Location
The pumpset is designed for installation in a
he inlet port of the housing must be at least DN40. It
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.
T
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
OTE: Debris e.g. welding slag, pipe scale,
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.
N
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
When measuring and marking for port alignment, be
ttom of
OTE: External position of inlet valve remote
he suggested method for ensuring correct angular
igure 2
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.
sure to allow for thickness of cathodic gasket.
Clearance of 5mm (min) is required between bo
pumpset and bottom (inside) of pump housing. Should
underside of pump touch housing, severe mechanical
damage will result and electrical insulation will be
negated.
N
handle does not necessarily determine port
alignment. Only rely upon actual measurements
taken from the inside of the pump housing.
T
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.
F

3.2.4 Discharge Riser
To determine dimension ‘A’ (Refer to Figure 3): g inlet
2. et length (to
4.
ength of the riser (discharge pipe)
ange) must be fitted with a
1. Determine (measure) depth of pump housin
port centreline from top of turret cover (X).
Add thickness of isolation gasket (Y).
3. Subtract 855mm to allow for pumps
centre line of inlet port).
A=X+Y-855
The result is the l
from the end of the thread to the underside of the pump
housing cover (flange) (A).
he top of the riser (above flT
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
ngth of conduit – ‘C’
. Determine height of discharge riser above
2.
3. allow for minimum conduit length
he result is the minimum overall conduit length
required (C).
rret Cover to
Inlet Port X= (measured)
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 le
(Refer to Figure 3 and Table 1):
1underside of flange (Z) (to top of 1" (F) NPT thread).
Add length of discharge riser pipe determined
previously (A).
Add 90 mm to
required for fittings.
4. C=Z+A+90
T
Table 1
Top of Tu
umpset
P
Centreline
Gasket Thickness Y =
RX33 Installation
allowance -855
Riser Length in Housing = X+Y-855A
Required Riser above
Gasket ite requirement)
Z=
(s
Discharge Riser Length A+Z
Coaxial Conduit Length
(Min) Z+90C= A+
3.2.6 Pumpset & System Piping Connections
Refer to Appendix A - P&ID for system arrangement
ing stresses
be transferred to the pum
Two con pu
NPT female thread
female thread.
o ns on pumpset require a
e with the manufacturer's
nds.
tely
etermined prior to any installation. Cutting
onduit with wires installed is not recommended.
and relative positioning of components.
It is extremely important
that no pip
pset.
mpset are required for
installation:
nections to
1. The discharge pipe (riser)
2. The electrical conduit
The discharge port has a 1-1/2"
n 3/4" NPTa d the conduit port has a
th NPT threaded connectioB
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
ecured in accordancs
(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
nd sharp edges must be removed from conduita
e
Figure 4
OTE: Conduit length should be accuraN
d
c
WARNING
WARNING
7

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 wi andring damage 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.
not to
h is
NO
to asket may not
8.
tor leads.
e three set screws
10
rge riser to achieve angular alignment.
12
3. Fit conduit over motor leads taking great care
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 whic
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.
TE: This must be done before fitting pumpset
riser as the Cathodic Insulation g
fit over the pumpset.
Figure 5
. To help prevent d
installation, fit the wire
the Electrical Fitting
Figure 6
amaging wires during
protection tube provided in
Kit over wires and half way
6
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.
While keeping the motor leads taut, guide the
discharge riser over the conduit taking great care
not to damage the mo
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 th
in the top of the pumpset. This fitting should be gas
tight.
.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)
discha
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.
.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
he discharge riser assembly with
appropriate thread sealant or tape, ensuring 8 full
NO age. Once this
Co
cu
15 cal position.
bly into the pump housing making sure that
fitting to t
threads minimum engagement. This fitting must be
gas tight.
TE: Do not tighten nut at this st
nut is tightened, the only way of removing the
nnector Housing from the discharge riser is by
tting through this fitting and the conduit.
.Carefully lift the pumpset/discharge riser assembly
rtiinto a ve
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
assem
the pumpset does not bind or drag on the sides of
the pump housing.
WARNING

NOTE: Before the pumpset/discharge riser
assembly is completely inside the pump housing,
Ca
tur
at the pumpset/discharge riser is
19.
tralian
NO
ele .
b)
to avoid
seal to hex nipple.
be fitting to 3/4"(F)
f)
g)
n tag over
ure 7
an ds.
T
24 ead to the conduit to
NO
tur
8.Coil the leads in the Junction Box.
remove the adhesive tape holding the cathodic
insulation gasket to the pump housing cover.
refully fit the cathodic insulation gasket to the
ret 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 th
electrically insulated from the tank. If not insulated,
rectify as required.
Determine basic location and orientation of Junction
Box, DPS etc. Based on this determination,
assemble Electrical Fitting Kit (Aus
Certification only) and DPS as follows:
TE: Do not use tape or sealant on NON-GAS
ctrical connections
a) Remove Junction Box cover.
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
damaging electrical leads.
c) Fit 25mm hex nipple to Junction Box.
d) Fit 25(F)M side of wire
e) Fit 3/4" NPT compression tu
NPT side of wiring seal.
Fit 25mm plug/s to unused Junction Box port/s.
Fit 25mm barrier gland to Junction Box.
20.Fit duplicate pumpset/motor identificatio
motor leads and over conduit as shown in Fig
21.Remove adhesive tape from wire protection tube
d slide tube off motor lea
22.Slide wire protection tube half way into
compression fitting. See Figure 7 3/4" NP
23.While holding the wire protection tube in place,
carefully slide the motor leads through the wire
protection tube and into the Junction Box.
.Test the resistance from each l
ensure that they are electrically insulated. Rectify
any fault as required.
25.Mount Junction Box to insulated support bracket if
required.
TE: If Junction Box requires a support
bracket, this must be electrically insulated from the
ret 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.
2
29.Fit cover and gasket to Junction Box.
3.2 arge Pipe Fittings.8 Disch
1. A DN25 (min) full bore pneumatically actuated
ball valve is required immediately downstream of
the Discharge Riser to isolate the discharge line.
25 (min) branch is
required for connection to the EBSRAY Inline
3.
4. T with a 'Tee'
2. After this ball valve, a DN
RV18-NRV Bypass Valve.
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.
he line from the valve must be fitted
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 S (Differential Pressure Switch).9 DP
1. Fit the high pressure side 1/4" tube as mentioned
in 4 above.
A low pressure side (vapour pressur 2. e) port must be
ver. This
port is required to accept a valve for isolation of the
of the DPS.
as
ins
provided through the Pump Housing Co
pressure gauge plus the 1/4" tube fitting for the low
pressure side
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
stated above, ensure that they are electrically
ulated 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. ation
50 the underside of the turret cover and
NO
pos
the
the
Internal Mounting: The EBSRAY PPV™Valve
'Internal Mounting Kit' is intended for install
inside the tank, but outside the pump housing wall.
Ensure that the inverted 'U' tube is no more than
mm from
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.
TE: PPV
™
Valve must be mounted in a vertical
ition with the arrow pointing up and away from
pump housing. i.e. flow path is only out from
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.
9

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

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

12
tested prior
RED (2), ORANGE (3), the
damage to the Pumpset may result.
tage is correct and that all
components are compliant &
set will result, voiding Warranty.
......OPEN
in an approved manner from
the Pumpset Discharge Riser.
. Back off Bypass Valve Adjusting Screw fully i.e.
8. En
mi
3. Direction of rotation - This MUST be
to Pumpset operation by using a Phase
Sequence Indicator at the Pump Controller.
With Pumpset wiring at the Junction Box in the
order: BLACK (1),
power supply phase sequence must be a, b, c. (or
R,S,T.) (CLOCKWISE)
Do not run Pumpset in
reverse. Severe internal
4.Ensure supply vol
relevant electrical
adequate for the application.
Do not run Pumpset dry.
Severe internal damage
to the Pump
5. Valves should be in the following positions:
(see Appendix A – P&ID for locations)
Pump Housing Inlet Valve.........................OPEN
PPV™Isolation Valve.................................OPEN
Valves to both sides of DPS......................OPEN
Valves to both Pressure Gauges............... OPEN
Discharge Line Valve/s..............................OPEN
Vapour/Bypass Return Line Valve/s ..
Do not start Pumpset
against closed discharge
valve or with Pump Housing Inlet Valve
closed or throttled.
6. Ensure that Pumpset is LPG liquid filled by
removing all vapour
7minimum differential pressure.
sure DPS bypass time in PLC is set to required
nimum delay time for the site (See Section
.2)
sure ‘Run-On’ feature is enabled/disabled as
5.3
9. En
re
ur OR
quired for the site (See Section 5.3.3)
Exceeding 20 starts per
ho re-starting in
es after the last start may
e and permanent internal
N-OFF-TEST’ Selector switch
on Pump Controller is ‘OFF’
mp Controller is
less than 2 min
result in seve ut r
electrical damage to the motor.
10. Ensure Keyed ‘RU
11. Ensure circuit breaker (Q1) in Pu
‘OFF’.
12. Ensure MOL Current Cut-Out Selector is set to
FLA rating (see Appendix B or C) and MOL Reset
Selector is in automatic reset mode – position (A).
4.4 STARTUP PROCEDURE
A Pumpset Run Log is provided in Appendix E. Fill in
startup section of the log as indicated below.the
or
r
one
1 ny
diffe rea
taken into account whe
ess re in ning
set Run Log.
the
Pumpset or pumping system does not function
properly, immediately turn the keyswitch to 'OFF'
tify the problem).
7. Chec read
Appendix B or C) on T
Re
co n Log.
Valve.
or
. ot
ial
During this pro
Pump C 1,
Motor FL
10. Wh ) differential pressure is
11. e. Note differential
n first set in this
12. kPa (7Bar) @ 50Hz at this stage).
13. The w re
actuated) operation vi
ke
Dis
the
ma the nature of the
bef maximum differential pressure setting of
14.
C). This differential
setting required by
in place for
security.
F commissioning and testing it may be advantageous
fo two persons, with some means of communication,
stationed at the Pump Controller and the other
ioned at or near the pumpset location.stat
. Chec botk readings on
rence in static h pressure gauges. Note a dings as this will have to be
settinn g Bypass Valve.
Record vapour pr u the commissio
section of the Pump
2. Connect amp meter to Pump Controller lead(s) T1,
T2 or T3 outside Hazardous Area
3. Activate power to Pump Controller.
4. Switch "ON" Q1 circuit breaker in Pump Controller.
5. Turn key switch to 'TEST' at Pump Controller.
This will start Pumpset. (If any aspect of
and rec
6. Check system fu
im in to
to ap 00
nctionality, Pumpset should
build differential pressure up
- 600 kPa. (5 – 6 Bar)
Record discharge pressure in the commissioning
section of the Pumpset Run Log.
mediately beg
proximately 5
k that current ing is below FLA rating (See
T2, &1, T3.
cord T1, T2, & T3 current readings in the
mmissioning section of the Pumpset Ru
8 Ensure that liquid is flowing through By. pass
This should be detectable audibly (by listening)
by feeling the valve/pipework (by hand).
9 Screw in the Bypass Valve Adjusting Screw n
exceeding two turns per minute until a different
pressure of 700 kPa (7 Bar) is achieved.
NOTE: cedure check current at
T2 & T3 (Must not exceed
A rating - See Appendix B or C)
en 700 kPa (7 Bar
ontroller on T
reached, turn Pumpset off and leave off for
approximately 1 minute.
Restart Pumpset in 'TEST' mod
pressure reading. This may be slightly different to
when first set (This is a normal characteristic of
Bypass Valve operation whe
manner).
Reset differential pressure as required (do not
exceed 700
Record discharge pressure and T1, T2, & T3
current readings in the commissioning section of
the Pumpset Run Log.
Pumpset is no ady for automatic (dispenser
a terminals 1 and 2. Turn
yswitch on Pump Controller to ‘RUN’ mode. The
penser/Communication System will now initiate
running of the Pumpset.
NOTE: Running-in Period - Due to the precision
nufacturing tolerances and
sleeve bearing material, the Pumpset may need to
be run-in at 700kPa (7 Bar) for a period of time
ore the
the Bypass Valve may be reached.
After the run-in period, differential pressure can be
set to maximum (Do not exceed FLA rating of
Motor - refer Appendix B or
pressure is dependent upon
end user. Record any changes to the discharge
pressure in the Pumpset Run Log.
Do not exceed full load
Amps on any leg of Motor.
15. After any Bypass Valve adjustment, tighten
adjusting screw locknut and wire
WARNING
WARNING
WARNING
WARNING
WARNING

13
16. The startup procedure is now complete for the
RX33 Pumpset and Protection System.
1 Inspect Pumpset/pumping system frequently during
the first few hours of operation, then periodically
7.
ing for LPG
tc.
PG in tank.
d
onl
and in the storage tank has stabilised to
boil cteristic
NOTE: Dispensing/pumping may be interrupte
(Pumpset stopped) by DPS fault during tanker
unloading operations. Resetting the RX33 must
y occur after unloading operation is completed
the LPG
thereafter. Record observations from these
inspections in the Pumpset Run Log . the new state/mix/temperature conditions - without
ing. This condition represents a chara
a) Inspect the pumping system check
leaks, vibration, unusual noises, e of LPG handling and not caused by the Pumpset or
pumping effects
b) Check the tank vapour pressure and the system
discharge pressure.
c) Check L1, L2 and L3 current, voltage and
balance between phases.
d) Check Pumpset run hours.
e) Check temperature of L
SECTION 5 – PUMP C TON ROLLER
Fig
rning the ‘RUN-OFF-
pos
doe
ure 10
All control voltages within
the Pump Controller are
220/240 Vac
Tu
TEST’ Keyed selector
switch to the ‘OFF’
ition, or switching Circuit Breaker Q1 ‘OFF’
s NOT isolate all electrical supplies to the
ardous area. The installehaz r MUST provide an
EST’ key
NO
But
key
NOTE: This publication is specific to the L861002
Series of Pump Controllers. Ebsray offers
alternative pump monitoring and control equipment
for various applications/markets. Refer to IOM
supplied with the alternative Ebsray pump
monitoring and control equipment as required.
Contact your Ebsray authorised representative for
details.
Table 2 – Pump Controller Components
Item Description
DANGER
isolator and an emergency stop circuit that cuts
all supply to the Drive. All power to the Drive
must be cut before working on any of the
subsequent equipment in the hazardous area.
Door Latch Key and/or
‘RUN-OFF-T
should only be accessed by suitably trained and
qualified personnel (e.g. Service Maintainer)
TE: ‘VIEW SETTINGS AND LOGS’ Push
ton may be operated without the need to have
access.
1 Lockable Enclosure Latch
2 ‘RUN-OFF-TEST’ Keyed Selector Switch
3 ‘RESET’ Push Button
4 ‘View Settings and Logs’ Push Button
5 PLC with LCD Screen (see Section 5)
6 Motor Contactor – KM1
7 Motor Overload Relay – F1
7A MOL Current Cut-Out Selector
7B MOL Reset Selector: Manual (H) – Automatic (A).
Note: This must be set to the Automatic (A) Reset
Position
8 Circuit Breaker (Isolator) – Q1
9 Run Relay – KA1
10 Terminal Strip
DANGER
CAUTION

5.1 DESCRIPTION OF PUMP CONTROLLER
The L861002 Series of Pump Controllers are
designed to manage the RX Series Submersible
Pumpsets and pumping system as described in
Appendix A. There are three primary functions of the
Pump Controller:
–Normal operation,
–Pumpset/Pumping System F
Pumpset Protection Functions
–Pumpset/Pumping System Diagn
ault Detection and
ostics
5.2 ACTIONS
5.2.1 Initial Settings
There are six buttons on the PLC as per:
WTSXMenu/OK
Main Settings Reset Logs Enter Shift
Menu
The following instructions will refer to t
their symbol WTSXor symbol
Shift
Defaul
he buttons as
plus Enter or
t screen upon power up.
5.2.2 To Set Date & Time
Time & pea
Date will ap :MM DD/MM r in the format YYHH /YY
Press the Shift + Xbuttons
The display will flash on the Hours to be changed
Press Tor Sto decrease or increase value.
Press Xto move to Minutes
Press Tor Sto decrease or increase value.
Press Xto move to Day
Press re
Press Mo
Tor Sto dec
Xto move to a
Press Tor Sto decrease or increase value.
se or increase value.
nth
Press Tor Sto decrease or increase value.
Press Xto move to Year
Press Enter to save settings
5.2.3 To Set DPS Time (Max 45s)
Press Tto show Status Settings screen
re ttons (Display Flashes)P ss the Shift + Xbu
Press Tor Sto decrease or increase value. (in
1/100s)
Press Enter to save setting
5.2.4 To View Settings & Set ‘Run-On’ Time
(Valid Options 0 or 2mins)
Press Tto show Status Settings screen
Press Sto toggle between 0 or 2
Press Wto save setting and return to Main Screen
5.2.5 View Logs
Press Xto toggle through the three Log Screens
5.2.6 To Reset a Critical Fault
NOTE: A critical fault cannot be reset unless
e Faulth t Screen displays ‘Reset Allowed’.
he ‘OFF’
p n
Press S
Th no will be
dis ye
Sw h he ‘RUN’
position
Switch the ‘RUN-OFF-TEST’ switch to t
ositio ‘RESET’ Push Button on door.
to Run’ screene rmal ‘Pump Ready
pla d.
itc the ‘RUN-OFF-TEST’ switch to t
5. O3 N RMAL OPERATION
5.3.1 ‘RUN’
–W en , the Pump
Controll set automatically
wh a voltage free contact signal
fr he closes/opens.
h the key-switch is in ‘RUN’
er starts/stops the Pump
en normally open,
om t dispenser(s)
5.3.2 DPS Bypass Timer
The Pump Controller features an adjustable timer (0
45 seconds) that enables the Pumpset to start and
verriding the DPS. This
uild up pressure on start-
s factory set
sec ds and ca e ad sted ( bsolutely
nd i e
5.2.3 for
ent Procedure). When the Pumpset starts,
the Pump Controller displays ‘DPS Time’ in seconds.
to
run for a period of time, o
allows the Pumpset time to b
up without indicating any fault. The timer i
to 12 on n b ju only if a
requ tions, e.g. long dired) to suit site co i scharg
line to the dispensers. (See Section
Adjustm
14

This time displayed is the actual time it has taken for
the Pumpset to build the minimum required differential
pressure after each re-start.
5.3.3 ‘Run-On’ Time
The Pump Controller has a 2 minute ‘Run-On’ feature
which can be enabled/disabled as site conditions
dictate. When the ‘Run-On’ feature is enabled, the
Pump Controller will continue to run the Pumpset for a
minimum of 2 minutes after the initial run signal from
the dispenser.
The ‘Run-On’ feature protects the Motor from the
otentially damaging effects of rapid starting/cycling
y than 2 minute) vehicle
fill times ( hour for the
M fill time of the
vehicl e ‘Run-On’
feature should be enabled. The ‘Run-On’ feature is
factory set to disabled
p
typicall caused by short (less
Note: maximum 20 starts per
otor). If the site condition’s average
e is less that 2 minutes, then th
. Turning the key-switch to the
‘OFF’ position will stop the Pumpset regardless of
the ‘Run-On’ feature being enabled or disabled. (See
Section 5.2.4 for the ‘Run-On’ enable/disable
procedure). The status of the ‘Run-On’ feature can
be d ‘S ATUS SETTINGS’
Setermined on either the creen or on the ‘PUMP RUNN T ING’ Screen.
5.3.4 ‘TEST’
WT’ position, the Pump
C of the
d e Pumpset will continue to
ru sition.
W in , all other
fe as in
‘R of the ‘Run-On’ feature.
Tstart-
u e procedures e.g.
etting the bypass pressure.
rcumstances
is the Pump Controller to
be left in ‘TEST’ mode for conventional filling.
hen the key-switch is in ‘TES
ontroller starts the Pumpset independently
ispenser’s run signal. Th
n until the key-switch is turned to the ‘OFF’ po
hile the Pumpset is running ‘TEST’
atures of the Pump Controller are the same
UN’, with the exception
he ‘TEST’ feature is ONLY to be used to aid
p/commissioning maintenanc
s
Under no ci
5.3.5 Normal Operation PLC Displays
Indicates the Pumpset is
idle nd ready to run.
date are
(See
e
time and date).
ndicates the
actual time it has taken
for the Pumpset to build
the minimum required
differential pressure
after each re-start. The
3rd line displays the actual time that the pumpset has
been running since the last start. The 4th line
indic ’ feature:
R s enabled.
a
The time and
also displayed.
Section 5.2.2 to set th
Indicates the Pumpset is
running. The 2nd line
displayed i
ates the status of the 2 minute ‘Run-On
un-On Time=00002Min Indicates feature i
R .un-On Time=00000Min Indicates feature is disabled
5.4 PUMPSET/PUMPING SYSTEM FAULT
DETECTION & PROTECTION FUNCTIONS
If the Pump Controller detects that one of
param et or the Pumping System is
the
eters of the Pumps
oper ntroller will stop
the Pum arning on the LCD
oubleshooting for Evaluation and
Rectificati
he faults are divided into the following groups:T
5.4.1 Critical Faults
If the Pump Controller detects a Critical Fault, the
peration of the Pumpset is immediately halted. The
umpset cannot be restarted again until an
uthorised person (e.g. a service/maintenance
chnician) has a) evaluated the cause of the fault, b)
nd safe to do
Reset’
ected are:
o
P
a
te
rectified the fault and c) if appropriate a
so, reset the Pump Controller via the PLC’s ‘
button on the door of the enclosure. (See Section
5.2.6 for the Fault Reset Procedure).
Critical Faults that can be det
5.4.1.1 DPS Faults Pump Controller monitors the
DPS g.
Indicates the Pumpset
ot developed the
equired
while the Pumpset is runnin
has n
minimum r
differential pressure
before the DPS Time
has elapsed.
Controller c The Pump an be reset
has not maintained the
imum required
erential pressure
after
after the reason for the
Fault has been evaluated and rectified.
Indicates the Pumpset
min
diff the DPS Time has
elapsed. The Pump
Controller can be reset
after the reason for the
Fault has been evaluated and rectified.
5.4.1.2 MOL Faults Pump Controller monitors the
current draw of the Pumpset’s Motor via the Motor
Overload (MOL) relay while the Pumpset is running.
Indicates the Pumpset’s
current draw has
exceeded the maximum
allowable amperage
tripping the MOL relay. It
is not possible to reset
the Pump Controller
because the MOL relay
has not yet automatically returned to the normally
open position.
ating abnormally, the Pump Co
pset and indicate a fault w
screen (See Tr
on of all indicated Faults).
Indicates the fault as
described above,
except the MOL relay
has automatically
returned to the normally
open position. The
Pump Controller can be
reset after the reason for the fault has been evaluated
and rectified.
WA
RNING
Indicates a locked rotor
Motor current or short
circuit condition at
startup.
DO NOT reset this Fault
unless other means have
been employed to ensure
that the cause of this Fault has been rectified.
W
ARNING
15

5.4.1.3 HBT Faults The Pump Controller monitors
the Pumpset’s Bearing Cooling and Lubrication
(BCL™) liquid temperature via the High Bearing
Temperature (HBT) switch, embedded in the Motor.
Indicates that the
Pumpset’s BCL™liquid
has exceeded the
maximum allowable
temperature while the
Pumpset is running,
tripping the HBT switch.
r
as
e except
switch has now
d
It is to
becau itc
returned to the normally
not possible
se the HBT sw eset the Pump Controller h has not yet automatically
closed position.
Indicates the fault
described abov
the HBT
returned to it’s normally
closed position. The
Pump Controller can be
reset after the reason for
and rectified.the Fault has been evaluate
5.4.2 Preventative Faults
T
d
v
T
f
C
P
he Pump Controller has
etected a low tank level
ia a normally open, Low
ank Level switch (if
itted). The Pump
ontroller will allow the
umpset to run after the
storage tank is refilled and the Low Tank Level switch
opens. No other action is required.
5.4.3 Informative Faults
Indicates that the liquid
in the Storage Tank has
to its
as
rmally
exceeded the maximum
allowable temperature
while the Pumpset is
NOT running, tripping
the HBT switch. The
Pump Controller will not allow the Pumpset to start
until the HBT switch automatically returns
normally closed position.
Indicates the fault
described above except
the HBT switch has
returned to its no
closed position. The
Pump Controller will
allow the Pumpset to
start normally without a reset of the Pump Controller
.
, the normal
n above will be
t
t
NOTE: After this fault has occurred
‘PUMP RUNNING’ screen will be displayed while
the Pumpset is running. However, when the
Pumpset is stopped, the scree
he service/maintenance
has occurred at some
5.5 PUMPSET/PUMPING SYSTEM DIAGNOSTICS
The Pump Controller stores
PLC which is useful fo
maintenance, troubleshootin
displayed on the PLC’s L
accessed from either the ‘
push button on the front of
buttons on the front of th
Run-On Time=00000Min Indi
various information in the
r system diagnostics,
g, etc. This information is
CD screen and can be
View Settings and Logs’
the enclosure or by the
e PLC, internal to the
enclosure. (See Section 5.2.4 & 5.2.5 for the Viewing
Settings and Logs Procedures).
The information that is stored and can be viewed is:
The ‘Settings’ screen
displays the curren
displayed again to alert
technician that the even
earlier time.
t
DPS time setting (See
Section 5.2.3) and the
status of the 2 minute
‘Run-On’ feature (See
Section 5.2.4).
cates feature is disabled.
cates feature is enabled.Run-On Time=00002Min Indi
The 1st Log screen
displays the Pumpset’s
NOTE:
NOTE: pe
total run hours.
In the event the Pumpset is changed, the
displayed Run Time at change-out must be
recorded.
The 2nd Log screen
displays the number of
specific MOL, DPS or
FHBT aults and the
hours and
nce the last
time (in
minutes) si
Fault.
Only one ty of specific fault will be
recorded should two successive faults occur. The
ump Controller will only record the last typePof
fault. If this type of fault is repeated, the PLC will
continue to record the accumulated number of
this type of fault, until a different type of fault is
recorded.
The 3rd Log screen
indicates:
- the number of Pumpset starts per hour for the
current hour.
- the maximum number of Pumpset starts per hour
in the last 24 hours
- the maximum number of
during the life of the Pum
NOTE: 20 starts per ho
these ‘Starts per Hour’
potentially damaging effec
cycling which must be
Pumpset starts per hour
pset.
ur or more in any of
Logs indicates the
ts of rapid starting and
rectified (See Section
5.3.3).
16

17
SECTION 6 – MAINTENANCE
Pr
dis
verify that all requireme
ior to any system
assembly or service,
nts of relevant Codes,
Regulations, Standards or Directives are met and
that specific site requirements etc are satisfied.
6.3 SERVICE EXCHANGE
CAUTION
E
toBSRAY maintains RX33 Service Exchange Pumpsets facilitate rapid and econom
the need arise. Contact E
representative to arrange.
(An EBSRAY Service Exch
reconditioned, ‘as-new’
Warranted item which has b
return for overhaul.)
ical changeover should
BSRAY or your local
nge Pumpset is a fully
performance, Factory
en in service prior to its
6.1 INSPECTION a
ePeriodic Inspection of the Pump System and Ancillary
Equipment is recommended
maximum interval of three
operation between routin
inspections (More freque
necessary dependent upo
operation etc).
Check:
e pressure.
c) Check L1, L2 and
balance between p
d) Check Pumpset ru
e) Check temperatur
If any condition is conside
critical nature, consult your
. EBSRAY recommend a
months or 500 hours
periodic maintenance
t inspections may be
usage, site conditions,
a) Inspect the Pumping System checking for
LPG leaks, vibration, unusual noises, etc.
b) Check the tank vapour pressure and the
system discharg
e
n
n6.4 SPARE PARTS
All Spare Parts for the RX33 Pumpset, Pump Controller
and/or Ancillary Equipment are readily available. (refer
to SERVICE above relating to restrictions as to the
extent of overhaul/repair only by certified/qualified
persons)
A spare parts listing is available to certified overhaulers
or repairers trained and appro ed by EBSRAY.
v
L3 current, voltage and
hases.
hours.
of LPG in tank.
ed to be of an urgent or
service provider or your
EBSRAY representative immediately. Record
bservations in the Pumpset Run Log, Appendix E.
n
e
r
o
6.2 SERVICE
a) RX33 Pumpset
The RX33 Pumpset is an integrated unit which includes
a Certified explosionproof Electric Motor.
Pumpset overhaul/repair
can ONLY be conducted
y certified/qualified repairers of explosion
rotected electrical equipment and in addition, who
ave been trained and approved by EBSRAY.
y
Y
actory Service.
Refer to specific equipmen
rrect
b
DANGER
p
h
The RX33 Pumpset is designed to enable complete
overhaul if required.
Complete information regarding overhaul and repair of
RX33 Pumpsets is available to certified repairers
trained and approved by EBSRAY.
NOTE: Warranty will be void should unauthorised
disassembly be conducted.
b) Pump Controller and Ancillary Equipment.
All equipment supplied by EBSRAY can be serviced b
ompetent (qualified) persons, or returned to EBSRAc
for F t manufacturer’s Service
maintenance procedures.
s fitted with a factory
st
Instructions to ensure co
NOTE: Pump Controller i
coded PLC. This item mu maintain its original
ting function cologic to perform its opera rrectly.
logic will void Pumpset Warranty.
Refer to EBSRAY for specific information and
instructions. Tampering with or modifying PLC

SECTION 7 – TROUBLESHOOTING
Error
Con sible ause Remedy
Possible
Problem Pos dition C
Insufficient LP ge TankG in Storage Tank Fill Stora
Incorrect Bypass Valve setting. Adjust (Increase) Bypass Valve
setting to achieve required
differential pressure.
Bypass Valve jammed open Check Bypass Valve, remove any
obstruction, roughness, corrosion
etc.
Pumpse
-Restrict
bypass
Isolatio
t has
ion in ischarge system or
line e.
n Valv
Bypass EFV
Check all devices in the discharge
system and bypass line, remove
ockage, repair or replace as
quired
'Dead Headed'
d
g. Discharge
e, Bypass Valve, bl re
or Isolation Valve
closed
Excessive inle
solatio
fully Inlet Excess Flow Valve as required
t restriction
n Valve not opened Check / open Inlet Valve Check, repair or replace Inlet- Inlet I
- Faulty Excess Flow Valve
Tanker unload
Tank during di penser operation ation is completed and mix/temp/state has
stabilised in tank
i
sng into Storage Wait until unloading oper
Insuffic
- PPV™
ient liquid in Pump Housing
Valve not fully open Open PPV™Valve Isolation Valve
Normal w
ser ear after extended vice Reconditioning (certified persons ONLY) or Service Exchange
Pumpset required.
Power supply to Pumpset faulty
e.g. voltage
- loss of phase
- imbalance of phases
Check power supply (with
Pumpset running and with
Pumpset stopped):
a) To Main Switch Board
b) To Pump Controller
c) To Pumpset
- low/high
- etc
Differential
Pressure too low
Contact(s) or co
Contactor (KM il in Motor 1) faulty Check Contactor, repair or replace as required
Isolation Valves (low side and/or
high side) to DPS not open Open both Isolation Valves to DPS
DPS Sensor Lines damaged Repair or replace Sensor Lines
Discharge Valve not fully open Check Actuator/
open Discharge Valve
Incorrectly adjusted DPS Check DPS as per manufacturer's
instructions
DPS not
functioning or
unable to function
DPS Replace/repair DPS
correctly
Faulty
Circuit/Communications outside
p Controller faulty Check Circuit/Communications, repair or replace as requiredPum
Cables
Main S / connections between witch Board, Pump
Controller and DPS faulty
Check cables/connections, repair
or replace as required
C
ontrol Circuit not
Controller faulty See ‘Pumpset Will Not Run’ below
functioning
correctly
Pump
*** DPS FAULT ***
AFTER DPS BYPASS
TIME HAS ELAPSED
18

Error
Condition Possible Problem RemedyPossible Cause
Insufficient LP Tank Fill StoragG in Storage e Tank
Excess
e
Check/open Inlet Valve
place Inlet
e as required
ive inlet restriction
- Inlet Isolation Valve not opened
fully
- Faulty Inlet Excess Flow Valv
Check, repair or re
Excess Flow Valv
Incorrectly adjusted DPS turer'sCheck DPS as per manufac
instructions
as not
inimum
differenti l fore
has elapsed.
Pumpset h
reached m
a
pressure. be
DPS bypass time
Faulty DPS Replace/repair DPS
*** DPS FAULT ***
BEFORE DPS BYPASS
TIME HAS ELAPSED
DPS Bypass
Timer set too low
for site conditions
Long discharge line to Dispenser
ase DPS Bypass Timer to
site conditions
No liquid in discharge line e.g.
drained back through Dispenser's
Vapour Return or 'boiled off'
Extended delays between
Pumpset starts
Incre
suit site conditions (see Operating
Instructions for timer adjustment)
Note: Always set the DPS Bypass
Timer to the MINIMUM time
required for the
See DPS above See DPS above
Differential Pressure too low onsNormal wear after extended
service Reconditioning (certified pers ONLY) or Service Exchange
Pumpset required.
Differential
Pressure too high
- no flow or very
low flow through
Pumpset
or
Bypass EFV or Isolation Valve
e
s required
Restriction in discharge system
bypass line e.g. Discharge
Isolation Valve, Bypass Valve,
closed
Check all devices in the discharg
line or the bypass line. Adjust
(decrease) Bypass Valve setting,
repair or replace a
Restricted or
blocked BCL™
Breathers/Filters
in
ing If Pumpset will not run after reset,Dirt/debris/contaminated LPG Storage Tank or Pump Hous contact EBSRAY or Appointed
Representative
Circuit/Communications outside
Pump Controller faulty Check Circuit/Communications, repair or replace as required
Cables/connections
rd between , Pump
(HBT
Main Switch Boa
Controller and Pumpset
faultyswitch)
Check cables/connections, repair
or replace as required
OR
Control Circuit not
functioning
correctly
Fault in Pump Controller See ‘Pumpset Will Not Run’ below
Too frequent repeat run signals r of starts. (See Pump
from Dispenser (may be faulty
signal cycling)
Limit numbe
Controller – Section 5)
Check/repair dispenser signal
quality as required.
Control circuit/Pump Controller w
malfunction. (Run Relay cycling) See ‘Pumpset Will Not Run’ belo
Excessive
StartsPumpset
(more than 20
starts per hour)
OR repeated re-
starting in less
than 2 minutes
after last start Excessive manual resets of Pump
Controller after faults Remedy problem before resetting.
Pumpset
recirculating er left in ‘Test ulating to tank and
ller to ‘Run
continuously
Pump Controll
Mode’, recirc
increasing the LPG temperature
Switch Pump Contro
Mode’
High liquid temperature when
delivered
High liquid
temperature in
Storage Tank sly for
hat key
is not left in "TEST" position.
er
Refer to EBSRAY
Pumpset running continuou
extended period - ensure t
Allow liquid in tank to cool ov
time. Top up to maximum
allowable level with cool LPG.
or
Overheating in
ypass Mode’ age Tank.. ‘B Insufficient LPG in Stor Fill Storage tank.
PPV™Isolation Valve not open pen PPV™Isolation ValveOPPV™Valve not
functioning
correctly Blocked or faulty PPV™Valve spect PPV™Valve, replace if
ulty
In
fa
OR
Pumpset
recirculating
continuously
Pump Controller left in ‘Test
Mode’, recirculating to tank and
increasing the LPG temperature
witch Pump Controller to ‘Run
ode’
S
M
*** HBT FAULT ***
WHILE PUMP RUNNING
& SWITCH NOT RESET
Reset not allowed
*** HBT FAULT ***
WHILE PUMP RUNNING
& HBT SWITCH RESET
Reset allowed
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH NOT RESET
Run not allowed
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH IS RESET
Pump RUN allowed
19

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