Ebsray RC SERIES Guide

Publication # 1982-06 EN
EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
RC SERIES
MODELS RC20 & RC25
…. For LPG APPLICATIONS

2
CONTENTS
SECTION 1 – GENERAL.............................................................................................................................................. 4
1.1 INTRODUCTION................................................................................................................................... 4
1.2 TRANSPORTATION, PACKING & STORAGE ..................................................................................... 4
1.3 RECEIVING INSPECTION.................................................................................................................... 4
1.4 HANDLING............................................................................................................................................ 4
1.5 WARRANTY.......................................................................................................................................... 4
SECTION 2 – SYSTEM DESCRIPTION....................................................................................................................... 5
2.1 EBSRAY RC20/RC25 LPG PUMPING SYSTEM.................................................................................. 5
2.2 BYPASS VALVE – EBSRAY MODEL RV18 (VRS OR CBS OPTIONS)............................................... 5
SECTION 3 – INSTALLATION..................................................................................................................................... 5
3.1 PUMP & SYSTEM LOCATION/INSTALLATION................................................................................... 5
3.1.1 Foundations................................................................................................................................... 5
3.1.2 Coupling........................................................................................................................................ 5
3.1.3 Strainer.......................................................................................................................................... 5
3.1.4 Pump Inlet ..................................................................................................................................... 5
3.1.5 Pump Discharge............................................................................................................................ 5
3.1.6 Bypass Valve................................................................................................................................. 6
SECTION 4 – OPERATION.......................................................................................................................................... 6
4.1 DESCRIPTION...................................................................................................................................... 6
4.2 LUBRICATION...................................................................................................................................... 6
4.3 PRE-STARTUP CHECKLIST................................................................................................................ 6
4.4 STARTUP PROCEDURE...................................................................................................................... 6
4.5 PERIODIC INSPECTION...................................................................................................................... 7
SECTION 5 – MAINTENANCE..................................................................................................................................... 7
5.1 PREPARATION FOR MAINTENANCE................................................................................................. 7
5.2 TO REPLACE MECHANICAL SEAL ONLY.......................................................................................... 7
5.3 TO REPLACE COMPLETE QUILL ASSEMBLY ONLY......................................................................... 7
5.4 DISASSEMBLY..................................................................................................................................... 7
5.5 INSPECTION ........................................................................................................................................ 8
5.6 SPARE PARTS ..................................................................................................................................... 8
5.7 REASSEMBLY - PRELIMINARY........................................................................................................... 8
5.8 REASSEMBLY...................................................................................................................................... 8
SECTION 6 – PARTS DESIGNATION ....................................................................................................................... 10
SECTION 7 – TROUBLE SHOOTING........................................................................................................................ 13
APPENDIX A – TYPICAL INSTALLATION P&ID – (ABOVEGROUND) ................................................................... 16
APPENDIX B – SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST............................................................. 17
APPENDIX C – EBSRAY PUMP RUN LOG............................................................................................................... 18
APPENDIX D – DECLARATION OF CONFORMITY ................................................................................................. 19
EBS-RAY PUMPS Pty. Limited
628 Pittwater Road
Brookvale NSW 2100 Australia
Phone: [phone])
Fax: [phone])
www.ebsraypumps.com.au
or Contact Ebsray Representative:

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 RC Series Pumps 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.
C
A
U
TI
ON
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.
ABBREVIATIONS:
AFL Automatic Fill Limiting Valve
CBS Constant Bleed System
EFV Excess Flow Valve
FLA Full Load Amps
VRS Vapour Removal System
3

SECTION 1 – GENERAL
4
1.1 INTRODUCTION
This publication is intended to assist those involved
with the installation, operation and maintenance of
Ebsray RC Series Regenerative Turbine Pumps and
the pumping system.
Before starting any work,
this publication should be
ed by all persons involved
with the work. If any part of this publication is
unclear, obtain clarification before proceeding
with any work.
completely read/review
flammable liquid, extrem
structions are intended to assist correct
hip incorporated
Installation and servicing
be performed by qualified competent personnel in
accordance with relevan
onents
ose manufactured by Ebsray e.g.
operated within the
original sign
produc G o
(ISO) quality and spec
As LPG (Propane and
Butane) is regarded as a
e caution must be taken
to ensure total compliance with all necessary
Statutory Standards, Directives, Codes and
Regulations is fully understood and exercised in
the installation, operation and maintenance of
Ebsray RC Series pumps.
These in
pump installation, operation and maintenance
requirements. They are additional to, and do not
supersede or override any applicable statutory,
legal or regulatory requirements.
The design, materials and workmans
in the manufacture of Ebsray pumps make them
capable of reliable operation over a long working life.
Correct installation and operation is essential. Service
life is enhanced by periodic inspection and careful
maintenance.
of this equipment should
t Standards, Directives,
Codes, Regulations and site restrictions, in
conjunction with these instructions.
When the equipment supplied utilises comp
other than th
electrical equipment, switches, fittings, valves, etc
reference should be made to the original
manufacturer's data before installation or servicing is
commenced. Failure to observe these details may
void the Warranty.
The pumpset must be
selected de
t (Use only LP parameters of pumped f internationally accepted
ification), flow, pressure,
temperature, voltage and current. Should any
change be contemplated, please confer with
Ebsray in order to verify the suitability of such a
change
1.2 TRANSPORTATION, PACKING & STORAGE
Standard domestic packing is suitable for shipment in
NOTE: If Pump
covered transports. Pump ports must be sealed to
exclude ingress of condensation, moisture or foreign
material. When received on site the Pump must be
stored in a dry covered area..
is not installed and
DANGE
R
commissioned immediately, special preservative
techniq reques will be uired. (Refer to Ebsray).
e.g. If the Pump is installed, but not
commissioned, low pressure nitrogen can be
used to purge, seal and protect the Pump from the
effects of condensation and atmospheric
corrosion.
NEVER allow water or
DANGE
R
any corrosive product to
d
enter the pump (e.g. for hydrostatic testing of
pipework). Severe internal damage may result an
will void the Warranty
1.3 RECEIVING INSPECTION
SHORTAGES and/or DAMAGE: On receipt of
equipment, check all items against the dispatch
documents and inspect for damage. Any damage or
shortage incurred during transit should be noted on the
packing note and on both your own and the carrier's
copy of the consignment note. A claim should be made
immediately on the transport company.
Also advise Ebsray or their Appointed Representative.
Should a shortage be evident on receipt, notify Ebsray
immediately giving full details and packing note
number.
1.4 HANDLING
Do not drop Pumpset! Care should be taken in
moving/handling Pump/Pumpsets in order to minimise
stress on the internal components.
The Pump/Pumpset should be lifted in such a manner
as to ensure compliance with the relevant lifting codes.
Severe internal Pump damage may result if correct
handling and due care is not taken.
1.5 WARRANTY
1. All Ebsray manufactured pumps and equipment are
by Ebsray but
warranted as standard for one (1) year against
faulty workmanship and/or materials. Refer to
Ebsray PUMPS 'Standard Conditions of Sale and
Warranty' publication for details.
2. Ancillary equipment supplied
manufactured by others will be in accordance with
those manufacturer's written warranty conditions
WARNING
WARNIN
CAUTION
G

SECTION 2 – SYSTEM DESCRIPTION
5
2.1 EBSRAY RC20/RC25 LPG PUMPING SYSTEM
The RC Series Pumps are designed for installation
aboveground when connected to aboveground storage
tanks.
2.2 BYPASS VALVE – EBSRAY MODEL RV18
(VRS OR CBS OPTIONS)
The RC Series Pumps must be installed in conjunction
with a bypass valve - connected back-to-tank. The
EBSRAY Model RV18 fitted with VRS or CBS option is
recommended. (Refer Appendix A - P & ID for details)
The Bypass Valve plays a pivotal role in the overall
LPG system. It controls the following functions:
1. Maintains pump system differential pressure as
required for optimum flow rates.
2. Controls Differential Pressure to maintain pump's
and/or motor's correct operation within intended
maximum operating parameters.
3. VRS option, when fitted, ensures rapid vapour
passage for faster pump priming before acting in
it’s intended liquid handling mode.
Fig 1
SECTION 3 – INSTALLATION
njunction with these
instructions.
pressurise prior to work.
Installation and removal
of this equipment should
be performed by suitably qualified competent
personnel in accordance with relevant Directives,
Standards, Codes, Regulations, and site
restrictions - in co
Never loosen or remove
fittings, flanges, etc. while
under pressure (vapour pressure of LPG may be
very high), always isolate components or pipework
and de
3.1 PUMP & SYSTEM LOCATION/INSTALLATION
Refer to P&ID Appendix A for system arrangement and
relative positions of important components/equipment
3.1.1 Foundations
a) Pumpsets should be accurately and securely
installed. When mounted direct on a concrete
foundation, ensure that it has a solid footing and is
levelled on the pump mounting surfaces.
b) Ensure floor area and headroom allotted is
sufficient for inspection and maintenance. Allow for
crane or hoist access if require
It is extremely important
that no piping stresses
be transferred to the
pump.
3.1.2 Coupling
When using the coupling supplied by Ebsray – refer to
Drg A316001C Rev C in Section 6. It is important that
the sleeve moves freely in the axial direction
NOTE: Couplings must be of the non-sparking
design and be in compliance with the relevant
Directives, Standards, Codes & Regulations
CAUTION
3.1.3 Strainer
The pump inlet must always be protected by an
efficient strainer of adequate size to accommodate the
flow rate conditions without causing excessive inlet
sistance or cavitation.re
DANGER
3.1.4 Pump Inlet
a) The pump is designed for installation with an
adequately sized inlet pipe with continuous fall from
that the pump and its
pipework
OTALLY
the LPG liquid withdrawal outlet of the tank.
b) Ensure this aboveground (exposed) inlet piping is
the shortest length possible – combined with the
minimum diameter (without causing cavitation) – thus
reducing the contained ‘vapour volume’ when priming.
c) Protection from direct sun will enhance pumping
performance by minimising vaporisation in pump and
inlet pipe. EBSRAY recommends
inlet pipework are painted white.
NOTE: Debris e.g. welding materials, pipe scale,
grinding swarf, shot blast material etc. left in the
pipework or tank will cause serious pump damage
and void the Warranty. Clean tank and
Tprior to pumpset installation.
WARNING
3.1.5 Pump Discharge
Discharge pipe size is generally dependent upon run
lengths at the specific site. Calculate as required to
ensure optimum conditions and to minimise pressure
drop.

6
3.1.6 Bypass Valve
Bypass Valve (Ebsray Model RV18-VRS or CBS)
(Refer Appendix A - P & ID for details) is installed on
the pump discharge side and returns back-to-tank. It
may be mounted directly on the 'spare' discharge port or
in the discharge pipe (before any isolation valve). This
Bypass Valve is primarily for control of differential
pressure. (NOTE: Variation in tank vapour pressure has
a direct effect upon discharge pressure whilst constant
differential pressure is maintained).
If VRS option is used (Refer Appendix A - P & ID for
details), a critical function performed by this unique
Bypass Valve is its rapid vapour handling capability
during the pump start-up/priming cycle. (Also refer to
Ebsray RV18 Bypass Valve Brochure for details and
functionality.)
Ensure correct orientation i.e. flow is 'IN' from pump
discharge line and 'OUT' returns to tank.
NOTE: The Bypass Valve’s return-to-tank pipeline
MUST NOT have any restrictions which could
adversely affect or limit the vapour clearing
function during pump priming.
An Excess Flow Valve or other 'normally open' tank
valve is recommended/ preferred.
Flow of LPG during bypassing should return to Storage
Tank vapour space.
SECTION 4 – OPERATION
4.1 DESCRIPTION
1. Pump
The Ebsray RC Series pumps are designed for ultra
quiet operation pumping LPG of Internationally
accepted (ISO) quality and specification.
The Pump meets the requirements of Australian,
European ATEX and other International Standards
and Codes for use in potentially explosive
atmospheres.
2. Motor
Certified explosion protected IEC frame 90 or 100 B5
Flange Mount 50Hz 2880 RPM or 60Hz 3500 RPM
electric motors fit directly onto RC Series pumps.
The RC20 uses 1.5 or 2.2kW and the RC25 uses 2.2
or 3.0kW Motors which can be either supplied by
EBSRAY or customer supplied. Motor must be wired
with a correctly sized IEC class 10A thermal overload
relay, and set to no more than the FLA of the motor.
Ensure motor conformity with all necessary Directives,
Standards, Codes, Regulations and site requirements.
3. Coupling
Non-Sparking design (e.g. “polygear” type) – sized to
suit duty. Supplied by Ebsray or customer supplied.
4.2 LUBRICATION
The Ball Bearings for the RC Series pumps are
grease lubricated and 'sealed-for-life' design.
No 'in service' lubrication is required on EBSRAY's
RC Series Pumps.
For motor, refer to specific motor manufacturer's
recommendations.
4.3 PRE-STARTUP CHECKLIST
Refer to pre-start inspection checklist (Appendix B)
Do not run Pumpset dry.
Do not start Pump against
e. Severe internal damage
to the Pumpset will result, voiding Warranty.
closed Discharge Valv
4.4 STARTUP PROCEDURE
Fill in the ‘Pump Run Log’ provided in Appendix C
.
2. pressure gauge. the
6 Start Pumpset.
1 Ensure all conditions described in Pre-Startup
Checklist have been met.
Check reading on discharge
Record product vapour pressure in
commissioning section of the Pump Run Log.
3. Back-off Bypass Valve Adjusting Screw (screw to
maximum 'out' position).
4. Verify all site conditions and statutory requirements
have been met.
5. Briefly activate power (i.e. 'jog' motor) to verify
correct pump rotation. (Cast arrow on cover)
If any aspect of the
pumpset or pumping
system does not function properly, immediately
turn the pump 'off' and rectify the problem before
re-starting.
WARNING
7. After startup, pump should immediately begin to
build differential pressure. If pump does not
prime immediately, switch off to determine reason
and rectify before re-starting.
8. After startup, initially ensure that liquid is flowing
through Bypass Valve. This should be detectable
by listening or feeling the Bypass Valve.
Screw 'in' the Bypass Valve Adjusting Screw until
the required system differential pressure is
achieved.
Record discharge pressure in the commissioning
section of the Pump Run Log.
9. Check that motor current is below FLA rating.
Record motor current readings in the
commissioning section of the Pump Run Log.
NOTE: During this procedure, or at any time,
motor current must not exceed FLA rating of
motor.
10. Stop pump, restart and check for consistent results.
11. Record discharge pressure and current readings in
the commissioning section of the Pump Run Log.
WARNING
12. The Pumpset is now ready for normal operation.
13. After final Bypass Valve adjustment, tighten
adjusting screw locknut and seal for security.
14. The startup procedure is now complete.
15. Inspect Pumpset/pumping system frequently during
the first few hours of operation then periodically
thereafter (see Section 4.5 for frequency).
Record observations from these inspections in the
Pump Run Log.

7
4.5 PERIODIC INSPECTION
Periodic Inspection of the Pump, Pump System and
Ancillary Equipment is required to maintain safety,
conformity, operational functionality and reliability.
Ebsray recommends a maximum interval of three
months or 500 hours operation between routine
periodic maintenance inspections (More frequent
inspections may be necessary dependent upon
usage, site conditions, operation etc).
If any abnormal condition is discovered, cease
operation of pump immediately and take action to
rectify the problem. Record observations from these
inspections in Pump Run Log.
For safe operation, the following items should be
included in the routine periodic inspection:
a. Inspect the Pump for LPG leaks, vibration,
abnormal noises, signs of overheating,
discolouration, etc.
b. Inspect Coupling Assembly for signs of wear,
overheating, discolouration, etc.
c. Check Pump differential pressure
d. Check Motor Current.
e. Inspect motor for vibration, abnormal noises,
signs of overheating, discolouration, etc.
SECTION 5 – MAINTENANCE
5.1 PREPARATION FOR MAINTENANCE
Prior to any system disassembly or service, verify that all requirements of statutory
Codes, Regulations, Standards & Directives are met and that specific site
requirements etc are satisfied. Obtain the appropriate Work Permit if required.
CAUTION
Most maintenance tasks and inspections can be performed with the pump ‘in line’ so long as complete electrical
isolation, depressurising and purging procedures have been completed.
5.2 TO REPLACE MECHANICAL SEAL ONLY
5.3 TO REPLACE COMPLETE QUILL ASSEMBLY ONLY
Replace Ball Bearings at intervals not exceeding recommended operational hours. See
Section 5.5.3
The following instructions are for complete pump disassembly (This may not be required - depending upon scope of
maintenance)
5.4 DISASSEMBLY
(Refer Drg No A316001B – Section 6)
1. Remove Motor, Coupling Guards, Pump
Coupling half and Pump Shaft Key.
2. Remove Cover, Impeller and Impeller Key.
3. Unscrew four
grubscrews from
Cartridge. Ref Fig 2
4. Insert grubscrews
into the two
extraction holes and
screw in evenly to
extract Cartridge or
Quill Assembly.
Fig. 2
Fig 3 Complete Quill Assembly
NOTE: Complete Quill Assemblies are available
from EBSRAY as a 'Spare Part' to enhance speed
and efficiency of maintenance.
Removal Replacement
Follow steps in Section '5.4 Disassembly' in the
following order:
2,3,5,6,4,7.
Inspect relevant components as described in Section '5.5
Inspection' and repair or replace as required.
Follow steps in Section '5.8 Reassembly' in the
following order: 1,2,3.
Fit Cartridge to Body before fitting and securing
Mechanical Seal Assembly as shown in Fig 5.12 and
Fig 5.13
Then follow steps 10 and 11 in Section '5.8
Reassembly'
Removal Replacement
Follow steps in Section '5.4 Disassembly' in the
following order:
1,2,3,4,9.
Inspect relevant components as described in Section '5.5
Inspection' and repair or replace as required.
Follow steps 3 & 7 to 14 in Section '5.8 Reassembly'
CAUTION

Pump Fastener Torque settings
5. Remove Circlip
from end of Quill
Assembly.
5. Remove Circlip
from end of Quill
Assembly.
Refer Fig 4Refer Fig 4
M12 ISO Grade 8.8 85Nm
o t ngs 20Nm M tor Fas ener Torque Setti
M10 ISO Grade 4.6
M10 ISO Grade 8 (nut)M12 ISO Grade 4.6 30NmSO Grade 4.6 30Nm
M12 ISO Grade 8 (nut)
M12 ISO Grade 8 (nut)
Fig 4Fig 4
6. Remove Mechanical Seal Assembly (the
Coupling Guard retaining screws may be
screwed into the Impeller and/or Seal Assembly
to aid removal).
6. Remove Mechanical Seal Assembly (the
Coupling Guard retaining screws may be
screwed into the Impeller and/or Seal Assembly
to aid removal).
7. Remove Carbon
Seal Seat and Lip
Seal from
Cartridge.
7. Remove Carbon
Seal Seat and Lip
Seal from
Cartridge.
Refer Fig 5Refer Fig 5
Fig 5Fig 5
8. Remove Circlip and press Bearings from Shaft.8. Remove Circlip and press Bearings from Shaft.
9. Remove Dust Seal (Bearing) from Body.9. Remove Dust Seal (Bearing) from Body.
5.5 INSPECTION
1. Check Impeller and Seal Zone of Body for
damage or wear. Replace Impeller if blades
have been damaged or wear exceeds minimum
recommended dimensions. Refer Fig.6
MINIMUM IMPELLER DIMENSIONS mm
Pump Model RC20 RC25
Minimum worn width 8.86 9.86
Minimum worn diameter 109.86 109.86
Fig 6
2. Check Shaft for wear, damage or run-out.
Replace as required.
3. Inspect both Ball Bearings for wear. It is
recommended on major overhauls that Ball
Bearings be replaced.
4. Check Mechanical Seal components for wear or
damage. It is recommended on major overhauls
that Mechanical Seal components be replaced.
5. It is recommended that as a standard procedure,
all O-Rings be replaced at every overhaul or
when any disassembly is conducted.
5.6 SPARE PARTS
1. When ordering spare parts, to ensure a minimum
of delay and correct replacement to original
specification, ALWAYS quote the pump Serial
Number located on the nameplate of the pump.
2. Advise the name, Cat # and quantity required.
Refer to Drg No A316001B (Section 6)
3. Advise complete delivery instructions,
transportation, etc.
NOTE: Substitute or so-callled ‘equivalent’
item/spare parts are not recommended for use.
Compliance , safe operation and pump
performance may be severely compromised if
incorrect or substitute spare parts – including
Fasteners, O-Rings, Ball Bearings, etc – are used.
5.7 REASSEMBLY - PRELIMINARY
1. Ensure all parts are clean before assembly.
Remove any burrs.
2. Ensure Impeller maintains an accurate free sliding
. This is critical.
At all times
fit on Shaft and key
when
. Lightly lubricate O-Rings, Lip Seals and
handling and installing
mechanical seals, care must be taken to ensure
lapped faces and seats are not damaged.
Particular attention must be given to carbon seats
to prevent marking or chipping.
CAUTION
3Mechanical Seal Faces with a compatible good
quality detergent-free light oil before assembly.
5.8 REASSEMBLY
(Refer Drg No A316001B & A316001L - Section 6)
ill Assembly
. Fit Lip Seal to Cartridge.
it O-Ring to Seal
it Seal Seat to
Fig 8
Qu
1
(note position of lip)
Refer Fig 7
Bearing Replacement recommended no
t
exceeding 10,000 operational hours. Fig 7
2. a) F
Seat.
b) F
Cartridge.
Refer Fig 8
8

c) Press Seal Seat
in with fingers.
(Ensure complete
and square
engagement)
Refer Fig 9
Fig 9
3. Fit Primary O-Ring
to Cartridge then f
Secondary O-Ring.
it
Refer Fig 10
Fig 10
4. a) Fit IE Bearing to
Shaft.
(Note: this is an
interference fit)
(Note: Apply force
to inner race of
Bearing only.)
b) Lock Bearing in
position with Circlip.
Refer Fig 11
Fig 11
5. Fit DE Bearing to Shaft.
(Note: this is an
interference fit)
(Note: Apply force to
inner race of Bearing
only.)
Refer Fig 12
Fig 12
6. a) Fit Bearing/Shaft
Assembly into
Cartridge.
b) Fit Seal rotating
subassembly to
Cartridge/Shaft
Assembly.
Referf Fig 13
Fig 13
c) Press down and lock
in position with
Circlip.
(Fig 14)
Fig 14
Final pump assembly
7. Fit Dust Seal to Body.
(Note position of lip)
Refer Fig 15
Fig 15
8. To assist assembly,
lightly lubricate bore in
cartridge zone with a
compatible good
quality detergent-free
light oil and fit Quill
Assembly to Body.
9. Lock in place with 4
grubscrews. (apply
Loctite 243 or
equivalent to grubscrews) Fig 16
Refer Fig 16
10. Fit Key and Impeller.
Ensure Impeller
maintains an accurate
free sliding fit on Shaft
and Key. This is
critical
Refer Fig 17
Fig 17
11. Fit O-Ring to Cover and
fit Cover to Body.
Tighten bolts to required
torque as shown in
Section 5.8.
Refer Fig 18
Fig 18
12. Fit Key and Coupling half
to Pump (and Motor if not
already fitted).
Refer to Section 6:
Drawing No: A316001C
for dimensions.
(Apply Loctite 243 or
equivalent to grubscrews)
Tighten grubscrews. Fig 19
Refer Fig 19
13. Fit 'polygear' Coupling Element and securely
mount Motor to Pump flange.
Note: If IEC 100 frame motor is utilised, Motor
Adaptor Kit must be fitted first.
14. Fit Coupling Guards.
Reassembly is now complete.
9

SECTION 6 – PARTS DESIGNATION
PARTS DESIGNATION - EBSRAY MODELS: RC20 & RC25 (Refer Drawing No. A316001B)
Cat
# Description Qty
Cat
# Description Qty
1 Body 1 37 Coupling Guard 2
2 Cover 1 37A Setscrew -Coupling Guard 4
3 Impeller 1 38 Plug - Spare Port 1
4 O-Ring – Cover 1 39 Seal Drain Elbow 1
6 Bolt 4 55 Lip Seal - Secondary Seal 1
7 Plug –Gauge Tapping 2 56* Mechanical Seal Assembly 1
8 Key – Impeller 1 Incl #40 Seal Seat 1
21 Shaft 1 Incl #41 Rotating Seal Face 1
23 Ball Bearing – Inspection End 1 Incl #42 Seal Sleeve 1
24 Ball Bearing – Drive End 1 Incl #45 Seal Spring 6
25 Circlip – Bearing 1 Incl #46 O-Ring – Shaft 1
33 Dust Seal - Bearing 1 Incl #47 O-Ring – Seal Sleeve 1
34 Key – Pump Shaft 1 Incl #48 O-Ring – Seal Seat 1
36 Coupling Assembly 1 57 Cartridge - Mechanical Seal 1
incl #36D Half Coupling – Motor 1 57A Grubscrew 4
incl #36E Coupling Element 1 57B O-Ring – Cartridge Primary 1
incl #36P Half Coupling – Pump 1 57C O-Ring – Cartridge Secondary 1
58 Circlip - Mechanical Seal 1
Motor Attachment – IEC D90 B5 Motor Attachment – IEC D100 B5
29 Bolt – M10x40 4 35 Motor Adaptor Kit to suit D100 1
29A Spring Washer – M10 4 incl #29 Bolt – M12x50 4
29B Nut – M10 4 incl #29A Spring Washer – M12 4
incl #29B Nut – M12 4
incl #35A Motor Adaptor 1
incl #35B Stud – M10x40 4
incl #35C Nut – M10 4
incl #35D Spring Washer – M10 4
DIMENSIONS EBSRAY MODELS RC20 & RC25
10

11

12

SECTION 7 – TROUBLE SHOOTING
Symptom Possible Problem Possible Cause Remedy
Insufficient LPG in Storage tank Fill Storage tank
Inlet Valve not open Open Inlet Valve
Cover Pump/piping with sunshadeExcessive heating (sun) on inlet
piping and/or Pump Paint Pump/piping white
Pump unable to clear vapour due to
excessive restriction in Bypass
return-to tank line
Ensure unrestricted and fully open passage
back to tank, clear blockage and/or
restrictions
Excessive volume of vapour to be
cleared Inlet (suction) pipe too long/too large – Shorten/reduce diameter
Storage tank filling by tanker during
dispensing/pumping operation Wait until filling operation is completed and mix/temp/state has stabilised in tank
Pump not primed
Normal wear after extended service Service Pump
Pump
running but
will not
generate
adequate
differential
pressure
Incorrect pump
rotation Incorrect wiring to Motor Reverse rotation by rewiring Motor
Dispenser/Control/
Communications
System faulty
Control System not providing signal Repair Control System as required
Supply Power to Motor faulty Check Power Supply
Power Supply faulty
Contact(s) or Coil in Motor
Contactor faulty Check Contactor, repair or replace as required
No power to Motor Motor Overload tripped out Determine cause of trip-out before
resetting
Pump will
not run
Jammed Pump See Symptom ‘Pump Motor using
excessive power’
Incorrect Bypass Valve Setting. Adjust (decrease) Bypass Valve setting to
achieve required lower pressure.
Differential Pressure
too high
Discharge Valve not fully open Open Discharge Valve
Power Supply to
Pump Motor faulty Power Supply (incorrect voltage, phase imbalance or phase loss etc.) Check Power Supply (with Pump running and with Pump stopped):
a) To Main Switch Board
b) To Pump Motor
Dirt/debris/contaminate from
Storage Tank and/or inlet pipe Clean blockage from Pump, Storage tank and/or inlet pipe before restarting Pump
Pump jammed or
damaged internally
Impeller Damaged Replace Impeller and inspect for damage
to Body, Cover and Shaft.
Pump
Motor
using
excessive
power or
over-
heating
Motor rapid cycling Excessive starts per hour (refer
motor manufacturer) Inspect, repair or replace motor.
Limit starts per hour
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 or faulty Check Bypass Valve, remove any
obstruction, roughness, corrosion etc.
Pump 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 (suction) restriction
- Inlet Valve not opened fully
- Blocked inlet strainer
- Faulty Inlet Excess Flow Valve
Check / open Inlet Valve
Clean strainer
Check, repair or replace Inlet Excess Flow
Valve as required
Storage tank filling by tanker during
dispensing/pumping operation Wait until filling operation is completed and mix/temp/state has stabilised in tank
Normal wear after extended service Service Pump
Differential Pressure
too low
Discharge Valve not fully open Open Discharge Valve
Increase Differential Pressure
Discharge
Pressure
too low
Low vapour Pressure
in Storage Tank High% Butane in Storage tank
Increase Vapour Pressure
13

Symptom Possible Problem Possible Cause Remedy
Receiving Tank/Vehicle Tank
already full No problem exists
Insufficient LPG in Storage Tank Fill Storage Tank
Blockage in Pump inlet/discharge
line Clear blockage e.g. open Valve, Excess Flow Valve, Valve at Dispenser etc.
Insufficient system Discharge
Pressure (See Symptom
“Discharge Pressure too low”)
Increase Discharge Pressure
(See Symptom “Discharge Pressure too
low”)
Excessive pressure in Receiving
Tank/Vehicle Tank Allow Receiving Tank/Vehicle Tank to cool until pressure decreases
Malfunctioning AFL Valve or blocked
Filter in AFL Valve in Receiving
Tank/Vehicle
Repair, clean filter or replace AFL Valve
in Receiving Tank/Vehicle as required
Blocked Filter in Meter/Dispenser Check and clean or replace as required
Blocked Filter in Nozzle Check and clean or replace as required
Pump not primed with LPG Refer to Symptom “Pump running but will
not generate adequate differential
pressure” Section of this manual
Storage tank filling by tanker during
dispensing/pumping operation Wait until filling operation is completed and mix/temp/state has stabilised in tank
No
Tank/Vehicle
fill
Pump operating
(rotating) but fails to
deliver LPG
Dispenser malfunctioning or not
authorised correctly Re-authorise or check Dispenser as required.
Insufficient LPG in Storage Tank -
Pump Inlet (Suction) Port not fully
covered with liquid
Fill Storage Tank
Low Pump flow
Excessive pressure in Receiving
Tank/Vehicle tank As filling proceeds, temperature (and pressure) will fall - increasing fill rate
Low Discharge
Pressure (See Symptom “Discharge
Pressure too low”) (See Symptom “Discharge Pressure too low”)
Malfunctioning AFL Valve or
blocked filter in AFL Valve in
Receiving Tank/Vehicle
Repair, clean filter or replace AFL Valve
in Receiving Tank/Vehicle as required
Blocked filter in Meter/Dispenser Check and clean or replace as required
Blocked filter in Nozzle Check and clean or replace as required
Restriction between
Pumpset and Vehicle
tank
Blockage within Receiving
Tank/Vehicle's fill piping or
Receiving Tank/Vehicle Back-check
valve faulty
Clear blockage. Check, clean or replace
as required
Long discharge line and/or small
diameter Increase diameter or increase differential pressure
Blocked filters in discharge system Clean filters
Slow
Tank/Vehicle
fill
Excessive System
resistance to flow
High pressure drop equipment in
discharge system (e.g. nozzle,
dispenser, AFL valve, vehicle
pipework)
Select 'lower loss' equipment
14

Symptom Possible Problem Possible Cause Remedy
Obstruction in Pump Dirt/debris/contaminate in Pump Clean blockage from Pump, Storage tank
and/or inlet pipe before restarting Pump
Faulty EFV on inlet,
Bypass or Discharge EFV Spring faulty or EFV ports partially blocked Check EFV(s), repair or replace as required
Faulty Back-check
Valve in Discharge
Line
Inspect Back-check Valve:
Spring, Seat, Poppet, Flapper etc. Repair or replace Back-check Valve as required
Faulty/noisy Bypass
Valve Bypass Valve faulty, worn or
damaged Check Bypass Valve, adjust, repair or
replace as required
Excessive
Noise
and/or
Vibration
Motor / Pump ball
Bearings worn Normal wear after extended service Service Pump/motor
Insufficient LPG in Storage tank -
Pump Inlet (suction) Port not fully
covered with liquid
Fill Storage tank
Excessive Inlet (suction) restriction
- Inlet Valve not opened fully
- Faulty Inlet Excess Flow Valve
- Blocked inlet strainer
Check / Open Inlet Valve, repair or
replace Excess Flow Valve as required
Clean strainer
Pump cavitating or
drawing vapour
Pump 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 Line or
the Bypass Line, remove blockage, repair
or replace as required
"Pulsing"
flow or
Pump
losing
prime
Worn Pump Normal wear after extended service Service Pump
15

APPENDIX A – TYPICAL INSTALLATION P&ID – (ABOVEGROUND)
16

APPENDIX B – SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST
Date:________________ Pumpset Serial No. _______________________________
Location: __________________________________ Bypass Valve Model No / Serial No: ___________________
Installation Company:__________________________ Installer's Name: _________________________________
Indicate Inspection Satisfactorily Completed with a 5in the appropriate box
1. Check for leak free installation at Pump and pipe connections..............................................................................
2. Check for correct pipe/port orientation (check IN / OUT marking on Pump)..........................................................
3. Ensure voltage is correct and that all relevant electrical components are adequate for the application...............
4. Ensure motor overload relay setting does not exceed FLA of motor......................................................................
Do not run Pump in reverse.
WARNING Severe internal damage to the Pump may result.
5. Direction of rotation –
This MUST be tested prior to Pump operation (check marking on Pump) ....................................................
Do not run Pump dry.
WARNING Severe internal damage to the Pump will result, voiding Warranty.
6. Valves should be in the following positions:
(see Appendix A – P&ID for locations)
Pump Inlet Valve…................................................................OPEN…………………………………………… 
Valves to both Pressure Gauges..........................................OPEN…………………………………………… 
Discharge Line Valve/s .........................................................OPEN…………………………………………… 
Vapour/Bypass Return Line Valve/s.....................................OPEN…………………………………………… 
Do not start Pump against closed Discharge Valve or
WA
R
NING with Inlet Valve closed or throttled
7. Ensure Storage Tank has adequate liquid and Pump is liquid filled before starting motor………………………. 
8. Back off Bypass Valve Adjusting Screw fully i.e. Minimum differential pressure....................................................
Notes:
17

APPENDIX C – EBSRAY PUMP RUN LOG
INSTALLATION RECORD
PUMP
SERIAL No. MOTOR DETAILS. SITE DATE COMMISSIONED NUMBER OF HOSES SERVED INSTALLED BY COMPANY/PERSONNEL
COMMISSIONING RECORD
RUN
HOURS INSPECT
SYSTEM
OK MOTOR CURRENT
(AMPS) LPG
TEMP
(°C) BY
(NAME) NOTES
STORAGE
TANK
VAPOUR
PRESSURE
kPa (bar)
PUMP
DISCHARGE
PRESSURE
kPa (bar) L1 L2 L3
RUN LOG
RUN
HOURS INSPECT
SYSTEM
OK MOTOR CURRENT
(AMPS) LPG
TEMP
(°C) BY
(NAME) NOTES
STORAGE
TANK
VAPOUR
PRESSURE
kPa (bar)
PUMP
DISCHARGE
PRESSURE
kPa (bar) L1 L2 L3
18

APPENDIX D – DECLARATION OF CONFORMITY
19

NOTES
20