Ebsray R SERIES Guide

Publication # 1858-10 EN
EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
R SERIES
MODEL RX10
…. For Submersible
LPG APPLICATIONS
(50Hz & 60Hz)

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 RX10 SUBMERSIBLE LPG PUMPING SYSTEM.................................................................. 5
2.2 EBSRAY RX10 SUBMERSIBLE LPG PUMPSET................................................................................. 5
2.3 “THREE-TIER” PROTECTION SYSTEM .............................................................................................. 5
2.4 DPS (DIFFERENTIAL PRESSURE SWITCH) ...................................................................................... 6
2.5 BYPASS VALVE ................................................................................................................................... 6
2.6 PPV™VALVE (POSITIVE PRESSURE VENTILATION VALVE)............................................................ 6
2.7 PUMP CONTROLLER .......................................................................................................................... 6
SECTION 3 – INSTALLATION..................................................................................................................................... 6
3.1 SYSTEM INSTALLATION..................................................................................................................... 6
3.1.1 Location......................................................................................................................................... 6
3.1.2 Pumpset Installation...................................................................................................................... 6
3.1.3 Port Alignment............................................................................................................................... 7
3.1.4 Discharge Riser............................................................................................................................. 7
3.1.5 Electrical Conduit .......................................................................................................................... 7
3.1.6 Pumpset & System Piping Connections........................................................................................ 8
3.1.7 Recommended Order of Assembly ............................................................................................... 8
3.1.8 Discharge Pipe Fittings.................................................................................................................. 9
3.1.9 DPS (Differential Pressure Switch)................................................................................................ 9
3.1.10 Bypass Valve............................................................................................................................... 10
3.1.11 PPV™VALVE (Positive Pressure Ventilation Valve)..................................................................... 10
3.1.12 Leak Check ................................................................................................................................. 10
3.2 ELECTRICAL CONNECTIONS – PUMPSET AND SYSTEM ............................................................. 10
3.2.1 Junction Box................................................................................................................................11
3.2.2 DPS (Differential Pressure Switch).............................................................................................. 11
3.2.3 Connecting Cable........................................................................................................................ 11
3.2.4 Pump Controller .......................................................................................................................... 11
SECTION 4 – OPERATION........................................................................................................................................ 12
4.1 DESCRIPTION.................................................................................................................................... 12
4.2 LUBRICATION.................................................................................................................................... 12
4.3 PRE-STARTUP CHECKLIST.............................................................................................................. 12
4.4 STARTUP PROCEDURE.................................................................................................................... 12
SECTION 5 – PUMP CONTROLLER......................................................................................................................... 14
5.1 DESCRIPTION OF PUMP CONTROLLER......................................................................................... 14
5.2 ACTIONS ............................................................................................................................................ 15
5.2.1 Initial Settings.............................................................................................................................. 15
5.2.2 To Set Date & Time..................................................................................................................... 15
5.2.3 To Set DPS Time (Max 45s)........................................................................................................ 15
5.2.4 To View Settings & Set ‘Run-On’ Time (Valid Options 0 or 2mins) ............................................. 15
5.2.5 View Logs.................................................................................................................................... 15
5.2.6 To Reset a Critical Fault.............................................................................................................. 15
5.3 NORMAL OPERATION....................................................................................................................... 15
5.3.1 ‘RUN’........................................................................................................................................... 15
5.3.2 DPS Bypass Timer...................................................................................................................... 15
5.3.3 ‘Run-On’ Time ............................................................................................................................. 16
5.3.4 ‘TEST’.......................................................................................................................................... 16
5.3.5 Normal Operation PLC Displays.................................................................................................. 16
5.4 PUMPSET/PUMPING SYSTEM FAULT DETECTION & PROTECTION FUNCTIONS...................... 16
5.4.1 Critical Faults............................................................................................................................... 16
5.4.2 Preventative Faults...................................................................................................................... 17
5.4.3 Informative Faults........................................................................................................................ 17
5.4.4 Pumpset/Pumping System Diagnostics....................................................................................... 17
SECTION 6 – MAINTENANCE................................................................................................................................... 18
6.1 INSPECTION ...................................................................................................................................... 18
6.2 SERVICE............................................................................................................................................. 18
6.3 SERVICE EXCHANGE ....................................................................................................................... 18
6.4 SPARE PARTS................................................................................................................................... 18
SECTION 7 – TROUBLESHOOTING......................................................................................................................... 19
APPENDIX A – TYPICAL INSTALLATION P&ID ...................................................................................................... 24
APPENDIX B – RX10 3.7kW SUBMERSIBLE PUMPSET – OUTLINE DIMENSIONS AND SPECIFICATIONS...... 25
APPENDIX C – TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAM................................................... 26
APPENDIX D – SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST............................................................. 27
APPENDIX E – EBSRAY PUMPSET RUN LOG........................................................................................................ 28
APPENDIX F – CERTIFICATIONS & DECLARATIONS OF CONFORMITY............................................................. 28

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 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:
3

SECTION 1 – GENERAL
1.1 INTRODUCTION
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.
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 RX10
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 shipme
covered transports. Pumpset ports must be seal nt in ed 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
t the dispatch
Any damage or
equipment, check all items agains
documents and inspect for damage.
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
ets. A sling should be placed
set in order to minimise stress
damage may result if
moving/handling Pumps
under or around a Pump
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
dard for one (1) year against
/or materials. Refer to
ut in the current
RX10 Pumpsets -
AY Pump Controller
Y PLC installed and
agreement of an
are warranted as stan
faulty workmanship and
EBSRAY PUMPS 'Standard Conditions of Sale
and Warranty' publication for details. RX10
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
RX10 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. RX10 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 RX10 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 RX10 New or
Service Exchange Pumpset Warranty conditions.
SECTION 2 – SYSTEM DESCRIPTION
2.1 EBSRAY RX10 SUBMERSIBLE LPG
PUMPING SYSTEM
The sy nd the RX10 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 RX10 is designed as a 'fully serviceable'
Pumpset.
Figure 1
2.2 EBSRAY RX10 SUBMERSIBLE LPG
PUMPSET
EBSRA ing Cooling and Lubrication
, cool LPG at pump
ring is a
te differential pressure is critical to
Y BCL™(Bear
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 the pumpset’s
service life and performance.
A - B (see Figure 2) operationAt all times during
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) Upper Motor BeaDirectly above the
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.
maintain this internal flow and to maintain the
liquid state of the LPG
NOTE: Adequa
Figure 2
2.3 “THREE-TIER” PROTECTION SYSTEM
The EBSRAY "Three-Tier" Protection System forms an
a res
er The
integr l part of the Pumping System which ensu
prop Pumpset performance. (Refer Warranty)
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.
5

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
3.
thr
fo tected by an interlock with keyed
developed above the minimum level within a preset
time after startup.
'MOL' (Motor OverLoad) Operation of the system
will be halted if Motor current exceeds a preset
maximum setting.
Automatic Pumpset shutdown from any of the above
ee functions requires access to the Pump Controller
r reset. Reset is pro
‘RUN-OFF-TEST’ switch. i.e. the fault can be isolated
for 'controlled' assessment and fault rectification prior to
reset and re-start.
2.4 DPS (DIFFERENTIAL PRESSURE SWITCH)
To ensure adequate (lubrication/cooling) flow through
e Pump/Motor internals, overall pumping system
ren
th
diffe tial 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
2.5 BYPASS VALVE
he EBSRAY RV18-NRV Bypass Valve plays a pivotal
le in the overall LPG system. It controls the following
Pumpset BCL System
Tier"
T
ro
functions:
1. Maintains Pump System differential pressure as
required for optimum flow rate into vehicles.
2. Enables the RX10 ™
pressure requirements to be met and maintained.
3. Forms an integral part of the overall "Three
protection system function.
4. Softseat 'backcheck' function helps to eliminate
LPG drain-back when Pumpset is idle.
2.6 PPV™VALVE (POSITIVE PRESSURE
VENTILATION VALVE)
The PPV™Valve's low opening/closing pressure allows
equalisation of liquid level in the Pump Housing when
mpset is not operating. Inthe Pu 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
2.7 PUMP CONTROLLER
The L861002 Series Pump Controller houses the PLC
that monitors and
pset. Pumping
and associated control circuits
controls the operation of the Pum
System information is displayed on an LCD screen.
For other Pump/System Controllers – refer to
EBSRAY for details.
SECTION 3 – INSTALLATION
Installation and removal of this equipment should be performed by suitably qualified
competent personnel in accordance with relevant Codes, Regulations, Standards,
Directives and site restrictions - in conjunction with these instructions.
CAUTION
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.
DANGER
3.1 SYSTEM INSTALLATION
3.1.1 Location
The Pumpset is designed for installation in a Pump
Housing/Chamber which is installed in, and thus forms
part of the pressure vessel. This housing is constructed
from DN150 (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 DN50. It
is isolated from the tank with a remotely operated
DN50 (full bore) ball valve. In addition, in some
countries, an excess flow valve designed for the duty is
fitted.
The centre height of the inlet port must be 45mm (min)
above the bottom (inside) of the housing. (See
Appendix A – P&ID)
3.1.2 Pumpset Installation
Pumpset should hang vertically from the Discharge
welding slag, pipe scale,
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 housing is straight and
free from intrusions and/or debris. The Discharge Riser
must be concentric with, and perpendicular to, the
Pump Housing Cover.
OTE: Debris e.g.N
grinding swarf etc. left in the Pump Housing can be
drawn into the Pumpset casing causing serious
damage and voiding the Warranty. Clean Pump
Housing TOTALLY prior to Pumpset installation.
When installed, the Discharge Riser Flange must be
totally insulated from the Turret Cover by means of a
Cathodic Insulation Gasket and insulated spacers at
the fastenings.
6

3.1.3 Port Alignment
NOTE: Accurate alignment of the Pumpset inlet
h the Pump Housing port is critical for
aximum performance
ickness of Cathodic Gasket.
n of inlet valve remote
rily determine port
angular
ort alignment is to mark the edge of the Pump
port wit
efficient Pumpset operation.
Vertical and angular alignment must be within ±5mm
for the Pumpset to operate to m
without cavitation.
When measuring and marking for port alignment, be
sure to allow for th
Clearance of 5mm (min) is required between bottom
of Pumpset and bottom (inside) of Pump Housing.
Should underside of Pumpset touch housing, severe
mechanical damage will result and electrical
insulation will be negated.
NOTE: External positio
ecessahandle does not n
alignment. Only rely upon actual measurements
taken from the inside of the Pump Housing.
The suggested method for ensuring correct
p
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. See Figure 3. and Appendix B.
Figure 3
3.1.4 Discharge Riser
To determine dimension ‘A’ (
See Figure 4):
using inlet
port centreline from top of Turret Cover (X).
3. gth (to
ength of the Discharge Riser from the
nd of the thread to the underside of the Pump
Housing Cover (flange) (A).
for the conduit exit,
igure 4
1. Determine (measure) depth of Pump Ho
2. Add thickness of Isolation Gasket (Y).
Subtract 982mm to allow for Pumpset len
centre line of inlet port).
4. A=X+Y-982
The result is the l
e
The top of the Discharge Riser (above flange) must be
fitted with a coaxial splitting arrangement which
provides a 1" (F) NPT thread
concentric and parallel with the Discharge Riser plus a
discharge connection
F
3.1.5 Electrical Conduit
The following relates to Coaxial conduit connection as
hown in Figure 4. For Parallel conduit connection
Discharge Riser) refer to
e Riser pipe determined
able 1
Port
e (measured)
s
(external to and parallel to the
EBSRAY or Appointed Representative
To determine minimum overall length of conduit – ‘C’
(See Figure 4 and Table 1):
1. Determine height of Discharge Riser above
underside of flange (Z) (to top of 1" (F) NPT thread).
. Add length of Discharg2 previously (A).
3. Add 90 mm to allow for minimum conduit length
required for fittings.
4. C=Z+A+90
The result is the minimum overall conduit length
required (C).
T
Top of Turret Cover to
Pumpset Inlet X=
Centrelin
Gasket Thickness Y =
RX10 Installation
allowance -982
Discharge Riser Length +Y-982
in Housing A = X
Required Discharge
Riser above Gasket Z= (site requirement)
Discharge Riser Length +ZA
Coaxial Conduit Length
(Min) C= A+Z+90
7

3.1.6 Pumpset & System Piping Connections
Refer to Appendix A - P
and rel &I arrange ent
Two co Pu
installation:
Discharge Riser
2. The Electrical Conduit
female thread. Both NPT
r umpset require a thread
SME B1.20.1-1983.
mmendations. Ensure correct
NO y
etermined prior to an
onduit with wires installed i
D for system m
ative positioning of components.
It is extremely important
that no piping stresses
be transferred to the Pumpset.
nnections to mpset are required for
1. The
The discharge port has a 2" NPT female thread and the
tcondui port has a ¾" NPT
th eaded connections on P
engagement as per ANSI/A
EBSRAY recommend at least 8 full turns for correct
installation and sealing.
The Tube Connectors for electrical conduit supplied by
and/or recommended by EBSRAY must be fitted and
secured in accordance with the manufacturer's
Swagelok or equal) reco(
positioning prior to tightening. Once tightened, the axial
position of fittings on the conduit cannot be altered and
any changes will require replacement of conduit and
fittings. (27 mm x 29 mm AF tube spanner is required)
Prior to fitting any wiring
into conduits, all burrs
and sharp edges must be removed from conduit
nds.e
Figure 5
TE: Conduit length should be accuratel
y installation. Cutting
s not recommended.
NO WELDING
d
c
is to be
r
nd/or wiring damage and
performed on any part of
the system (discharge piping, vapour returns or
conduits) with Pumpset/wires installed. Failure to
bserve this warning could result in severe Motoo
a void the Warranty.
3.1.7 Recommended Order of Assembly
1. Support the Pumpset in the horizontal position.
. Fit straight 3/4" NPT compression tube fitting to the
conduit port of the Pumpset with appropriate thread
sealant or tape. t.
not
no-go gauge which is
2
NOTE: This connection must be gas-tigh
3. Fit conduit over Motor Leads taking great care
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
approximately 1¾ turns after hand tight.).
NOTE: This connection must be gas-tight.
Fit Cathodic Insulation5. Gasket over Discharge Riser
pset.
and temporarily secure to Pump Housing Cover
with adhesive tape.
NOTE: This must be done before fitting
Pumpset to Discharge Riser as the Cathodic
Insulation Gasket may not fit over the Pum
Figure 6
Figure 8
amaging wires during
protection tube provided in
Kit over wires and half way
ily secure with adhesive
Figure 7
. To help prevent d
installation, fit the wire
the Electrical Fitting
into conduit. (temporar
tape) See Figure 8
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
8.
tor Leads.
WARNING
WARNI
WARNING
NG
8

9. Fit Discharge Riser assembly to the Pumpset with
appropriate thread sealant or tape. With the
Pumpset stationary, screw Discharge Riser into
e Pumpset. This
10.
12 rews
Pumpset ensuring 8 full threads minimum
engagement. The end of the thread of the
Discharge Riser must completely overlap the three
set screws in the top of th
connection 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)
Discharge Riser to achieve angular alignment.
11.Check overall length of Pumpset/Discharge Riser
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 sc
against Discharge Riser.
NOTE: These screws must be tight
Lubricate the protruding conduit with light oil to
prevent galling
13. when fitting the 1" NPT bored-
14. Riser assembly with
suring 8 full
through compression tube fitting.
Fit the 1" NPT bored-through compression tube
fitting to the Discharge
appropriate thread sealant or tape, en
threads minimum engagement.
NOTE: This connection must be gas tight.
TE: Do not tighten nut at thisNO stage. Once this
cu
15. rge Riser assembly
he
18. Riser is
NO
NO
d DPS as follows:
c
d le.
e) Fit 3/4" NPT compression tube fitting to 3/4"(F)
20.Fi Figure 6
be
l T
y insulated. Rectify
25 rt bracket if
ted from
28.
nut is tightened, the only way of removing the
connector housing from the Discharge Riser is by
tting through this fitting and the conduit.
Carefully lift the Pumpset/Discha
into a vertical position.
NOTE: When raising or lowering the
Pumpset/Discharge Riser assembly, take care
not to damage the Pumpset, Motor Leads or
conduit. Lift carefully with slings, chains etc.
16.Carefully lower the Pumpset/Discharge Riser
assembly into the Pump Housing making sure that
psthe Pum et does not bind or drag on the sides of
the Pump Housing.
NOTE: Before the Pumpset/Discharge Riser
assembly is completely inside the Pump
Housing, remove the adhesive tape holding t
Cathodic Insulation Gasket to the Pump
Housing Cover. Carefully fit the Cathodic
Insulation Gasket to the Turret Cover.
17.Fit Pump Housing Cover to Turret Cover with
appropriate cathodic insulators/washers for bolts
and nuts. Align marks on Pump Housing Cover and
Turret Cover. The seal between the Pump Housing
Cover and the Turret Cover must be gas tight.
Check that the Pumpset/Discharge
electrically insulated from the tank. If not insulated,
rectify as required.
TE: Do not use sealing tape or sealant on
N-GAS electrical connections.
19.Determine basic location and orientation of Junction
Box, DPS etc. Based on this determination,
assemble Electrical Fitting Kit (Australian
Certification only) an
a) Remove Junction Box cover.
b) Fit DPS to Junction Box (For Junction Boxes
which are not fitted with a 1/2" NPT(F) thread, use
adaptor supplied) Take care when fitting to avoid
damaging electrical leads.
) Fit 25mm hex nipple to Junction Box.
) Fit 25(F)M side of Conduit Seal to hex nipp
NPT side of Conduit Seal.
f) Fit 25mm plug/s to unused Junction Box port/s.
g) Fit 25mm Barrier Gland to Junction Box.
t duplicate Pumpset/Motor identification tag over
otor Leads and over conduiM t as shown in
21.Remove adhesive tape from wire protection tu
and slide tube off Motor Leads.
22.S ide wire protection tube half way into 3/4" NP
compression fitting. See Figure 6
23.While holding the wire protection tube in place,
carefully slide the Motor Leads through the wire
protection tube and into the Junction Box.
24.Test the resistance from each lead to the conduit to
ensure that they are electricall
any fault as required.
.Mount Junction Box to insulated suppo
required.
NOTE: If Junction Box requires a support
bracket, this must be electrically insula
the Turret Cover and Tank.
26.Trim excess wire from Motor Leads and DPS Leads
(leave adequate length for connection without
tension).
27.Temporariliy cap the free ends of the leads with
insulating tape ensuring that the cores are covered.
Coil the leads in the Junction Box.
29.Fit Cover and Gasket to Junction Box.
3.1.8 Discharge Pipe Fittings
1. ownstream of
discharge line.
) branch is
required for connection to the EBSRAY Inline
RV18-NRV Bypass Valve.
p rge line to accept an
of the DPS via a ¼" OD SS tube.
A DN25 (min) full bore pneumatically actuated
ball valve is required immediately d
the Discharge Riser to isolate the
2. After this ball valve, a DN25 (min
3. A ort is required in the discha
isolation valve. This valve is for isolation of the
pressure gauge and the high pressure side of the
DPS.
4. The line from the valve must be fitted with a 'Tee'
arrangement to connect to a 0-2500kPa (0–25
Bar) pressure gauge and to the high pressure side
3.1.9 DPS (Differential Pressure Switch)
1. Fit the high pressure side ¼" tube as mentioned
in 4 above.
A low pressure side (vapour pressure) port must be
provided through the Pump Hous
2. ing Cover. This
port is required to accept a valve for isolation of the
pressure gauge plus the 1/4" tube fitting for the low
pressure side of the DPS.
9

3. The line from the valve must be split with a 'Tee'
arrangement. One side of the 'Tee' feeds an inlet
NO
oth , ensure that they are
pressure gauge (0-2500 kPa) (0 – 25 Bar) and the
other side feeds the low pressure side of the DPS
via a ¼" OD SS tube.
TE: If any components are fitted in a position
er than as stated above
10
electrically insulated from the Turret Cover, Tank
etc.
3.1.10 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
ve are also required to be
3. ver. A hydrostatic
(min) excess flow val
fitted to the bypass line.
The Bypass Valve return line must be electrically
insulated from the Tank/Turret Co
relief valve must be fitted in this line as the RV18-
NRV Bypass Valve is also a back-check valve.
3.1.11 PPV™VALVE (Positive Pressure Ventilation
Valve)
NOTE: 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.
pos
the
the
™
ins nk, but outside the Pump Housing wall.
B.
the
A. Internal Mounting: The EBSRAY PPV Valve
'Internal Mounting Kit' is intended for installation
ide the ta
Ensure that the inverted 'U' tube is no more than
50mm from the underside of the Turret Cover and
remains in the vapour space of the Tank at all
times. A secondary shut off valve must be installed
between Pump Housing and the PPV™Valve and
must be operable from above the Turret Cover.
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
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.
3.1.12 Leak Check
1.
nd Gasket from Junction Box.
e DPS pressure lines.
ve
4.
Figure 9
5. Remove tape from conduit, refit compression tube
fitting to conduit. Tighten nut on fitting as shown in
Figure 7
6. Refit Cover and Gasket to Junction Box.
Tighten nut on 1" NPT bored through compression
fitting as shown in Figure 7
2. Remove Cover a
3. Carefully raise Junction Box to expose the Motor
Leads and the top of the conduit. Take care not to
damage Motor Leads on th
Seal off Motor Leads to conduit with adhesi
tape. (See Figure 9)
Leak check all conduit and other pressure
connections.
3.2 D SYSTEMELECTRICAL CONNECTIONS – PUMPSET AN
Important Electrical Installation Notes
d installation is only to be carried out by suitably qualified personnel.
des, Regulations, Standards, Directives
and site restrictions, as ap
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
Typ
m
Installer must provide additional items as shown in
tic and
DANGER
1. All construction an
2. All construction is to be strictly in accordance with relevant Co
plicable 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.
ical electrical connections are as shown in the
accompanying diagrams Figure 10 and Appendix C.
Ite s provided by EBSRAY are suitable for use in the Appendix C – Typical Wiring Schema Connection Diagram.
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.
NOTE: All gland, conduit, wiring terminations and
connections are to be strictly in accordance with
manufacturers instructions and relevant
Standards, Codes, Regulations and Directives.

Figure 10
3.2.1 Junction Box 3.2.4 Pump Controller
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.
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 a,b,c (clockwise) phase sequence.
3. Isolate power from Pump Controller.
4. Connect leads from cable to terminal strip in
Junction Box (See Figure 10) then refit Junction
Box Cover and Gasket.
5. Remove plug from Conduit 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
One (1), Three (3) and Four (4) respectively on the
terminal strip in the Pump Controller (Any extra
unused cores should be capped off). The ground
core is connected to the Earth Terminal.
See Section 5 for further details on Pump Controller.
3.2.2 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.
3.2.3 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.
11

SECTION 4 – OPERATION
4.1 DESCRIPTION
T
w
T
clo
Pu
In
T
Eu
Co
T
af
c
he RX10 Pumpset is designed to provide trouble-
free & safe operation in potentially explosive
environments provided it is operated in accordance
ith the following recommendations.
1. Pumpset
he EBSRAY Model RX10 Pumpset is a compact
se-coupled Submersible Regenerative Turbine
mp/Motor unit, designed for pumping LPG of
ternationally accepted (ISO) quality and specification.
he Pumpset meets the requirements of Australian,
ropean ATEX and other International Standards and
des for use in potentially explosive atmospheres.
2. Motor
he Submersible Electric Motor is designed to meet
the requirements of Australian, European ATEX and
other International Standards and Codes. The Motor
is Certified for the specified area and application (See
APPENDIX F). (Refer maximum starts per hour
WARNING this section)
Severe internal damage
to the Pumpset will result
if unauthorised or uncontrolled resetting occurs
ter any fault symptom is indicated on the Pump
Controller. Before resetting, correct the fault. Refer
to Section 7 - Troubleshooting.
Warranty will be void if unauthorised resetting is
onducted without first correcting the fault.
4.2 LUBRICATION
No 'in service' lubrication is required on EBSRAY's
Model RX10 Pumpset.
4.3 PRE-STARTUP CHECKLIST
Record pre-start inspection on checklist (Appendix D)
.
2.
wiring at the Junction Box in the
order: BLACK (1), RED (2), ORANGE (3), the
, b, c. (or
o not run Pumpset dry.
vere internal damage
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........ OPEN
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 in an approved manner from
the Pumpset Discharge Riser.
7. Back off Bypass Valve Adjusting Screw fully i.e.
minimum differential pressure.
8. Ensure DPS bypass time in PLC is set to required
minimum
WARNING
delay time for the site (See Section
5.3.2)
9. Ensure ‘Run-On’ feature is enabled/disabled as
required for the site (See Section 5.3.3)
Exceeding 20 starts per
hour OR
WARNING
1 Check that all electrical wiring is insulated from
the ground, conduits, tank etc.
Check for leak-free installation at Pumpset, pipe
and electrical conduit connections.
3. Direction of rotation - This MUST be tested
prior to Pumpset operation by using a Phase
Sequence Indicator at the Pump Controller.
With Pumpset
power supply phase sequence must be a
R,S,T.) (CLOCKWISE)
Do not run Pumpset in
reverse. Severe internal
damage to the Pumpset may result.
4.Ensure supply voltage is correct and that all
relevant electrical components are compliant &
adequate for the application.
D
Se
to the Pumpset will result, voiding Warranty.
re-starting in
less than 2 minutes after the last start may result in
severe and permanent internal electrical damage to
the Motor.
10. Ensure Keyed ‘RUN-OFF-TEST’ Selector switch
on Pump Controller is ‘OFF’
Q1) in Pump Controller is
WARNING
11. Ensure circuit breaker (
‘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)
(See Figure 11).
4.4 STARTUP PROCEDURE
A Pumpset Run Log is provided in Appendix E. Fill in
the startup section of the log as indicated below.
For commissioning and testing it may be advantageous
for two persons, with some means of communication,
one stationed at the Pump Controller and the other
stationed at or near the Pumpset location.
1. Check readings on both pressure gauges. Note
re in the commissioning
h to 'OFF'
any difference in static readings as this will have to
be taken into account when setting bypass Valve.
Record vapour pressu
section of the Pumpset Run Log.
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 the
Pumpset or pumping system does not function
properly, immediately turn the keyswitc
and rectify the problem).
WARNING
WARNING
12

13
. Check system functionality, Pumpset should
immediately begin to build differential
up to approximately 500 - 600 kPa. (5 – 6
sure in the commissioning
readings in the
ning section of the Pumpset Run Log.
During this procedure check current at
t
)
1. Restart Pumpset in 'TEST' mode. Note differential
s
s
Bypass Valve operati
ion of
the Pumpset Run Log.
w ready for automatic
nd
UN’
er/Communication System will
now initiate the running of the Pumpset.
Pum under automatic
app tial pressure
tting s
14.
es to in
og.
o no oad
Amps on r.
16 The startup procedur
RX1 Pr
17. Inspect Pumpset/Pumping System frequently
the first few hours of operation, then
ally thereafter.
Record observations from these inspections in the
Pumpset Run Log.
a) Inspect the Pumping System checking for LPG
the system
d
NOTE: pu
(Pumps y D
G in the Storage Tank has stabilised to
wit
cha nd not caused by
6pressure
Bar) during periodic
Record discharge pres
section of the Pumpset Run Log.
7. Check that current reading is below FLA rating
(See Appendix B or C) on T1, T2, & T3.
Record T1, T2, & T3 current
commissio
8. Ensure that liquid is flowing through Bypass
Valve. This should be detectable audibly (by
listening) or by feeling the valve/pipework (by
hand).
9. Screw in the Bypass Valve Adjusting Screw not
exceeding two turns per minute until a differential
pressure of 700 kPa (7 Bar) is achieved.
NOTE:
Pump Controller on T1, T2 & T3 (Must no
exceed Motor FLA rating - See Appendix B or C
10. When 700 kPa (7 Bar) differential pressure is
reached, turn Pumpset off and leave off for
approximately 1 minute.
1pres Thi
whe s i
sure reading.
n first set (Thi may be slightly different to a normal characteristic of
on when first set in this
manner).
12. Reset differential pressure as required (do not
exceed 800kPa (8Bar) @ 50Hz or 700 kPa (7 Bar)
@ 60Hz at this stage).
Record discharge pressure and T1, T2, & T3
current readings in the commissioning sect
13. The Pumpset is no
(dispenser actuated) operation via terminals 1 a
2. Turn keyswitch on Pump Controller to ‘R
mode. The Dispens
Running-in Period
Due to the precision
manufacturing tolerances
and the nature of the sleeve bearing material, the
pset should be run-in
(dispenser actuated) operation (‘RUN’ mode) for
roximately 20 hours. The differen
se hould not exceed 800kPa (8 Bar) @ 50Hz
or 700 kPa (7Bar) @ 60Hz during this period.
After the 20 hour run-in period, differential
pressure can be set to maximum (Do not exceed
FLA rating of Motor - refer Appendix B or C). This
differential pressure is dependent upon setting
required by end user.
Record any chang
the P the discharge pressure umpset Run L
D t exceed full l
any leg of Moto
15. After any Bypass Valve adjustment, tighten
Adjusting Screw Locknut and wire in place for
security.
e is now complete for the
otection System.
leaks, vibration, unusual noises, etc.
b) Check the tank vapour pressure and
discharge pressure.
c) Check L1, L2 and L3 current, voltage an
balance between phases.
d) Check Pumpset run hours.
e) Check temperature of LPG in Tank.
Dispensing/
et stopped b mping may be interrupted PS fault) during tanker
unloading operations. Resetting the RX10 must
only occur after unloading operation is completed
and the LP
the new state/mix/temperature conditions -
hout boiling. This condition represents a
racteristic of LPG handling a
the Pumpset or pumping effects.
0 Pumpset and
WARNING
WARNING
13

14
SECTION 5 – PUMP CONTROLLER
Fig
e Pump Controller are 220/240 Vac
Door Latch Key and/or ‘RUN-OFF-TEST’ key should only be accessed by suitably
t l (e.g. Service Maintainer)
ay be operated without the need to have key access.
ure 11
All control voltages within th
DANGER
rained and qualified personne
NOTE: ‘VIEW SETTINGS AND LOGS’ Push Button m
CAUTION
Item Description
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 1Motor Contactor – KM
7 Motor Overload Relay – F1
7A ut-MOL Current C Out Selector
7B ectMOL Reset Sel or: Manual (H) – Automatic (A).
Note: This must be set to the Automatic (A) Reset
Position
8 Circuit Breaker (Isolator) – Q1
9 elay – KA1Run R
10 Terminal Strip
able 2 – Pump Controller Components
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 Fault Detection and
Pumpset Protection Functions
–Pumpset/Pumping System Diagnostics
T

5.2 ACTIONS 5.2.4 To View Settings & Set ‘Run-On’ Time
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 the buttons as
their symbol a) WTSXor
b) Enter or Shift +WTSX
r up.Default screen upon powe
5.2.2 To Set Date & Time
Time & Date will appear in the format
HH:MM DD/MM/YYYY
Press the Shift + Xbuttons
The display will flash on the Hours to be changed
Sto decrease or increase value.
o move to Minutes
Press Tor Sto decrease or increase value.
Press Xto move to Day
Press Tor Sto decrease or increase value.
Press Xto move to Month
ase or increase value.
Yea
ase or increase value.
Press Enter to save settings
Press Tor
Press Xt
Press Tor Sto decre
Press
Press T
Xto move to
or Sto decre r
5.2.3 To Set DPS Time (Max 45s)
P sre s s screen
P ss s)
Press e. (in
1 00s
Press
Tto show Status Setting
re the Shift + Xbuttons (Display Flashe
or increase valuTor Sto decrease
/1 )
Enter to save setting
(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
the Fault Screen displays ‘Reset Allowed’.
F’
Press S‘RESET’ Push Button on door.
The normal ‘Pump Ready to Run’ screen will be
Switch the ‘RUN-OFF-TEST’ switch to the ‘RUN’
osition
Switch the ‘RUN-OFF-TEST’ switch to the ‘OF
position
displayed.
p
5.3 NORMAL OPERATION
5.3.1 ‘RUN’
When the key-switch is in ‘RUN’, the Pump Controller
starts/stops the Pumpset automatically when a
normally open, voltage free contact signal from the
dispenser(s) closes/opens.
5.3.2 DPS Bypass Timer
The Pump Controller features an adjustable timer (0
the DPS. This
on start-
p without indicating any fault. The timer is factory set
12 seconds and can be adjusted (only if absolutely
quired) to suit site conditions, e.g. long discharge
e to the dispensers. (See Section 5.2.3 for
djustment Procedure). When the Pumpset starts,
to 45 seconds) that enables the Pumpset to start and
run for a period of time, overriding
allows the Pumpset time to build up pressure
u
to
re
lin
A
15

the Pump Controller displays ‘DPS Time’ in second
his time displayed is the actual time it has taken for
mum required differential
s.
T
the Pumpset to build the mini
pressure after each re-start.
5.3.3 ‘Run-On’ Time
The p C er ha 2 minute ‘Run-O
c
Pum ontroll s a n’ feature
d o s
. When the ‘Run-On’ feature nab
which can be enabled/ isabled as site ndition
is e leddictate , the
Pump Controller will continue to run the Pumpset for a
he ‘Run-On m the
potenti y damaging effects of rapid starting/cycling
han 2 minute) vehicle
fill times (Note: maximum 20 starts per hour for the
Motor). If the site condition’s average fill time of the
vehicle is less that 2 minutes, then the ‘Run-On’
feature should be enabled. The ‘Run-On’ feature is
factory set to disabled
minimum of 2 minutes after the initial run signal from
the dispenser.
T ’ feature protects the Motor fro
all
typically caused by short (less t
. Turning the key-switch to the
‘OFF’ position will stop the Pumpset regardless of
un-On’ feature being nabled or disabled. (See
ection 5.2.4 for the ‘Run-On’ enable/disable
rocedure). The status of the ‘Run-On’ feature can
te ATUS SETTINGS’
S een.
the ‘R
Se
p
be de rmined on either the ‘ST
creen or on the ‘PUMP RUNNING’ Scr
5.3.4 ‘TEST’
When the key-switch is in ‘TEST’ position, the Pump
Controller starts the Pumpset independently of the
dispenser’s run signal. The Pumpset will continue to
run until the key-switch is turned to the ‘OFF’ position.
While the Pumpset is running in ‘TEST’, all other
features of the Pump Controller are the same as in
‘R un-On’ feature.
Trt-
u e.g.
s
nces
ler to
b .
UN’, with the exception of the ‘R
he ‘TEST’ feature is ONLY to be used to aid sta
p/commissioning maintenance procedures
etting the bypass pressure.
Under no circumsta
is the Pump Control
e left in ‘TEST’ mode for conventional filling
5.3.5 Normal Operation PLC Displays
dicates the Pumpset is
idle and ready to run.
and date are
played. (See
Section 5.2.2 to set the
time and date).
Indicates the Pumpset is
running. The 2nd line
displayed indicates the
actual time it has taken
et to build
uired
after each re-start. The 3 line displays the actual
ti n running since the last
tart. The 4 line indicates the status of the 2 minute
un-On’ feature:
un-On Time=00002Min Indicates feature is enabled.
In
The time
also dis
for the Pumps
the minimum req
differential pressure
rd
me that the pumpset has bee
th
s
‘R
R
un-On Time=00000Min Indicates feature is disabled.R
5.4 PUMPSET/PUMPING SYSTEM FAULT
DETECTION & PROTECTION FUNCTIONS
If the Pump Controller detects that one of the
arameters of the Pumpset or the Pumping System is
perating abnormally, the Pump Controller will stop
valuation and
Rectification of all indicated Faults).
The faults are divided into the following groups:
p
o
the Pumpset and indicate a fault warning on the LCD
screen (See Troubleshooting for E
5.4.1 Critical Faults
If the Pump Controller detects a Critical Fault, the
operation of the Pumpset is immediately halted. The
Pumpset cannot be restarted again until an
authorised person (e.g. a service/maintenance
technic
re afe to do
s
.2.6 for the Fault Reset Procedure).
detected are:
ian) has a) evaluated the cause of the fault, b)
ctified the fault and c) if appropriate and s
o, reset the Pump Controller via the PLC’s ‘Reset’
utton on the door of the enclosure. (See Sectionb
5
Critical Faults that can be
5.4.1.1 DPS Faults Pump Controller monitors the
DPS while the Pumpset is running.
Indicates the Pumpset
has not developed the
minimum required
differential pressure
before the DPS Time
has elapsed. The Pump
Controller can be reset
after the reason for the
ault has been evaluated and rectified.
Indicates the Pumpset
has not maintained the
minimum required
differential pressure
after
F
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
e the Pumpset is running.
es the Pumpset’s
current draw has
perage
Controller
described above,
t the MOL relay
automatically
returned to the normally
a locked rotor
Overload (MOL) relay whil Indicat
exceeded the maximum
allowable am
tripping the MOL relay. It
is not possible to reset
the Pump
because the MOL relay
has not yet automatically returned to the normally
open position. Indicates the fault as
excep
has
open position. The
Pump Controller can be
reset after the reason for the fault has been evaluated
and rectified.
Indicates
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.
WARNING
WARNING
16

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.
It is not possible to reset the Pump Controller
because the HBT switch has not yet automatically
returned to the normally closed position.
Indicates the fault as
described above except
the HBT switch has now
returned to it’s normally
closed position. The
Pump Controller can be
reset after the reason for
the Fault has been evaluated and rectified.
5.4.2 Preventative Faults
The Pump Controller has
detected a low tank level
via a normally open, Low
Tank Level switch (if
fitted). The Pump
Controller will allow the
Pumpset 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
imum
e
while the Pumpset is
OT running, tripping
all
auto
normally closed position.
fault as
bed above except
start normally without a reset
NOTE: After this fault h
o alert the service/maintenance
exceeded the max
allowable temperatur
N
the HBT switch. The
ow the Pumpset to start
matically returns to its
Indicates the
Pump Controller will not
until the HBT switch
descri
the HBT switch has
returned to its normally
closed position. The
Pump Controller will
allow the Pumpset to
of the Pump Controller.
as occurred, the normal
‘PUMP RUNNING’ screen will be displayed while
the Pumpset is running. However, when the
Pumpset is stopped, the screen above will be
displayed again t
technician that the event has occurred at some
earlier time.
5.4.4 Pumpset/Pumping System Diagnostics
The Pump Controller stores various information in the
stics,
s
D screen and can be
gs’
al to the
iewing
en
the current
setting (See
n’ feature (See
PLC which is useful for system diagno
maintenance, troubleshooting, etc. This information i
displayed on the PLC’s LC
accessed from either the ‘View Settings and Lo
push button on the front of the enclosure or by the
buttons on the front of the PLC, intern
enclosure. (See Section 5.2.4 & 5.2.5 for the V
Settings and Logs Procedures).
The information that is stored and can be viewed is:
The ‘Settings’ scre
displays
DPS time
Section 5.2.3) and the
status of the 2 minute
‘Run-O
Section 5.2.4).
icates feature is disabledRun-On Time=00000Min Ind .
icates feature is enabled.Run-On Time=00002Min Ind
The 1st Log screen
displays the Pumpset’s
total run hours.
umpset is changed, the
change-out must be
The 2nd Log screen
displays the number of
specific M
NOTE: In the event the P
displayed Run Time at
recorded.
OL, DPS or
NOTE: Only one type
HBT Faults and the
time (in hours and
minutes) since the last
Fault.
o
recorded should two succe
Pump Controller will only
f specific fault will be
ssive faults occur. The
record the last type of
fault. If this type of fault is
continue to record the a
this type
repeated, the PLC will
ccumulated number of
of fault, until a different type of fault is
recorded.
T
ihe 3rd Log screen
ndicates:
- the number of Pumpset starts per hour for the
current hour.
- the maximum number of
in the last 24 hours
- the maximum number of
e Pum
NOTE: 20 starts pe
these ‘Starts per Hour’ Logs
potentially damaging effec
cycling be
5.3.3).
Pumpset starts per hour
p
r hour or more in any of
indicates the
t of rapid starting and
Pumpset starts per hour
set.during the life of th
s
which must rectified (See Section
17

SECTION 6 – MAINTENANCE
6.3 SERVICE EXCHANGE
EBSRAY maintains RX10 Service Exchange Pumpsets
to facilitate rapid and economical changeover should
the need arise. Contact EBSRAY or your local
representative to arrange.
(An EBSRAY Service Exchange Pumpset is a fully
reconditioned, ‘as-new’ perf
Prior to any system
disassembly or service,
verify that all requirements of relevant Codes
CAUTION
,
Regulations, Standards or
that specific site requireme
Directives are met and
nts etc are satisfied.
6.1 INSPECTION
Periodic Inspection of the Pu
may be
on usage, site conditions,
i
system discharge p
c) Check L1, L2 and
d) Check Pumpset run hours.
e) Check temperatur
critical nature, consult your
EBSRAY representative
observations in the Pumpse
mp System and Ancillary
. EBSRAY recommend a
aximum interval of three months or 500 hours
peration between routine periodic maintenance
spections (More frequent inspections
ormance, Factory
s
turn for overhaul.)
Warranted item which has been in service prior to itEquipment is recommended
mre
o
inecessary dependent up
operation etc).
Check:
a) Inspect the Pump
LPG leaks, vibration
b) Check the tank v
n6.4 SPARE PARTS
All Spare Parts for the RX10 P
and/or Ancillary Equipment a
to SERVICE above relating
or repairers trained and appro
umpset, Pump Controller
re readily available. (refer
to restrictions as to the
ng System checking for
, unusual noises, etc.
apour pressure and the
ressure.
L3 current, voltage and
balance between phases.
extent of overhaul/repair only by certified/qualified
persons)
A spare parts listing is available to certified overhaulers
ved by EBSRAY.
e of LPG in tank.
be of an urgent or
t
If any condition is considered to
service provider or your
immediately. Record
Run Log, Appendix E.
18
6.2 SERVICE
a) RX10 Pumpset
tor.
Pu
protected electrical equip
have been trained and app
The RX10 Pumpset is des
overhaul if required.
Complete information regard
RX10 Pumpsets is availab
r specific instructions.
The Discharge Head of the
a tamper evident seal (see A
NOTE: Warranty will be
disassembly be conducte
This item must
The RX10 Pumpset is an integrated unit which includes
a Certified explosionproof Electric Mo
mpset overhaul/repair
LY be conducted
of explosion
m
r
i
can ON
by certified/qualified repairers
DANGER
ent and in addition, who
oved by EBSRAY.
gned to enable complete
ing overhaul and repair of
le to certified repairers
trained and approved by EBSRAY.
Prior to removal of the RX10 from its installation,
please contact EBSRAY or Appointed Representative
R
v
d
fo X10 Pumpset is fitted with
ppendix B)
oid should unauthorised
.
b) Pump Controller and Ancillary Equipment.
All equipment supplied by EBSRAY can be serviced by
competent (qualified) persons, or returned to EBSRAY
for Factory Service.
Refer to specific equipment manufacturer’s Service
Instructions to ensure correct maintenance procedures.
NOTE: Pump Controller is fitted with a factory
oded PLC.c maintain its original
gic to perform its operating function correctly.
efer to EBSRAY for specific information and
structions. Tampering with or modifying PLC
gic will void Pumpset Warranty.
lo
R
in
lo

SECTION 7 – TROUBLESHOOTING
Error
Condition Possible Cause Remedy
19
Possible
Problem
Insufficient LPG in Storage Tank Fill Storage Tank
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.
Pumpset has 'Dead Headed'
-Restriction in discharge system or
bypass line e.g. Discharge
Isolation Valve, Bypass Valve,
Bypass EFV or Isolation Valve
closed
Check all devices in the discharge
system and bypass line, remove
blockage, repair or replace as
required
Excessive inlet restriction
- Inlet Isolation Valve not opened
fully
- Faulty Inlet Excess Flow Valve
Check / open Inlet Valve
Check, repair or replace Inlet
Excess Flow Valve as required
Tanker unloading into Storage
Tank during dispenser operation Wait until unloading operation is completed and mix/temp/state has
stabilised in tank
Insufficient liquid in Pump Housing
- PPV™Valve not fully open Open PPV™Valve Isolation Valve
Normal wear after extended
service Reconditioning (certified persons ONLY) or Service Exchange
Pumpset required.
Power supply to Pumpset faulty
e.g.
- low/high voltage
- loss of phase
- imbalance of phases
- etc
Check power supply (with
Pumpset running and with
Pumpset stopped):
a) To Main Switch Board
b) To Pump Controller
c) To Pumpset
Differential
Pressure too low
Contact(s) or coil in Motor
Contactor (KM1) 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
correctly
Faulty DPS Replace/repair DPS
Circuit/Communications outside
Pump Controller faulty Check Circuit/Communications, repair or replace as required
Cables / connections between
Main Switch Board, Pump
Controller and DPS faulty
Check cables/connections, repair
or replace as required
Control Circuit not
functioning
correctly
Pump Controller faulty See ‘Pumpset Will Not Run’ below
*** DPS FAULT ***
AFTER DPS BYPASS
TIME HAS ELAPSED

Error
Condition Possible Problem RemedyPossible Cause
Insufficient LPG in Storage Tank Fill Storage Tank
Excessi
- Inlet
fully
- Fau
ve inl
Isolatio
lty Inlet
or replace Inlet
Valve as required
et restriction
Valve not opened Check/open Inlet Valve Check, repairn
Excess Flow Valve Excess Flow
Incorrectly ad sjusted DPS Check DPS as per manufacturer'
instructions
PS
Pumpset has not
reached minimum
differential
pressure. before
DPS bypass time
has elapsed.
Faulty D Replace/repair DPS
DPS Bypass
Timer set too low
for site conditions
Long d
No liqui
drained
Vapour
Extend
ischarg
d in di
back
Retur
ed del etween
Pumpset starts
Note: Always set the DPS Bypass
Timer to the MINIMUM time
required for the site conditions
e line to Dispenser
scharge line e.g.
through Dispenser's
n or 'boiled off'
Increase DPS Bypass Timer to
suit site conditions (see Operating
Instructions for timer adjustment)
ays b
See DPS above See DPS above
Differential
Pressure too low wear
Normal service after extended Reconditioning (certified persons ONLY) or Service Exchange
Pumpset required.
Differential
too high
low flow through
Restriction in system or
bypass line e
Isolation Valv
Bypass EFV or Isolation Valve
setting,
repair or replace as required
Pressure
- no flow or very
Pumpset closed
discharge
.g. Discharge
e, Bypass Valve,
Check all devices in the discharge
line or the bypass line. Adjust
(decrease) Bypass Valve
Restricted or
blocked BCL™
Breathers/Filters
Dirt/debris
Storage T/contaminated LPG in ank or Pump Housing If Pumpset will not run after reset, contact EBSRAY or Appointed
Representative
Circuit/Communications outside
Pump Controller faulty Check Circuit/Communications, repair or replace as required
Cables
Main S/connections between witch Board, Pump
Controller and Pumpset (HBT
ulty
Check cables/connections, repair
or replace as required
switch) fa
Control Circuit not
functioning
Pump Controller See ‘Pumpset Will Not Run’ below
OR
correctly
Fault in
Too frequent
from Dis
signal c
repeat run signals
penser (may be faulty
ycling)
Limit number of starts. (See Pump
Controller – Section 5)
Check/repair dispenser signal
quality as required.
Control circuit/Pump Controller
on. (Run Relay cycling) See ‘Pumpset Will Not Run’ below malfuncti
Excessive
Pumpset Starts
(more than 20
starts per hour)
OR repeated re-
starting in less
than 2 minutes
after last start Excess
Controller after
ive manual resets of Pump
faults Remedy problem before resetting.
Pumpset
recirculating Pump C Mode’, recircul
continuously increa
ontroller left in ‘Test
ating to tank and
sing the LPG temperature
Switch Pump Controller to ‘Run
Mode’
High liquid temperature when
delivered
High liquid
temperature in et running continuously for
extended period - ensure that key
is not left in "TEST" position.
Allow liquid in tank to cool over
time. Top up to maximum
allowable level with cool LPG.
or
Refer to EBSRAY
Storage Tank Pumps
Overheating in
‘Bypass Mode’ Insufficient LPG in Storage Tank.. Fill Storage tank.
PPV Isolation Valve not open Open PPV™Isolation Valve
™
PPV Valve not
d or faulty PPV™Valve Inspect PPV™Valve, replace if
faulty
™
functioning
correctly Blocke
OR
Pumpset
recirculating
continuously
Pump
Mode’, recircul
increasin
Controller left in ‘Test
ating to tank and
g the LPG temperature
Switch Pump Controller to ‘Run
Mode’
*** DPS FAULT ***
BEFORE DPS BYPASS
TIME HAS ELAPSED
*** HBT FAULT ***
HIL PUMP RUNNINGW E
& SWITCH NOT RESET
Reset not allowed
*** HBT FAULT ***
WHILE PUMP RUNNING
T
Reset allowed
& HBT SWITCH RESE
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH NOT RESET
Run not allowed
*** HBT ALARM ***
PUMP NOT RUNNING &
SWITCH IS RESET
Pump RUN allowed
20