Ebsray RC SERIES Guide

Publication # 1981-04 EN
EBSRAY PUMPS
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
RC SERIES
MODELS RC20 & RC25
…. For LPG Applications

2
CONTENTS
IMPORTANT NOTES.................................................................................................................................... 3
SECTION 1 – GENERAL.............................................................................................................................. 4
1.1 INTRODUCTION................................................................................................................................................ 4
1.2 TRANSPORTATION AND 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 ...................................................................................................... 5
SECTION 3 – INSTALLATION ..................................................................................................................... 5
3.1 PUMP & SYSTEM LOCATION/INSTALLATION................................................................................................ 5
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 & DIMENSIONS............................................................................ 10
SECTION 7 - TROUBLE SHOOTING......................................................................................................... 13
APPENDIX A - TYPICAL INSTALLATION P & ID.................................................................................... 16
APPENDIX B - PRE-STARTUP INSPECTION CHECKLIST .................................................................... 17
APPENDIX C - INSPECTION/RUN LOG .................................................................................................... 18
APPENDIX D - EC DECLARATION OF CONFORMITY........................................................................... 19

3
WARNING
DANGER
EBSRAY PUMPS Pty. Ltd.
628 PITTWATER ROAD PHONE: [phone]
BROOKVALE NSW 2100 AUSTRALIA FAX: [phone]
www.ebsraypumps.com.au
IMPORTANT NOTES
CE marking
1. This Publication is TYPICAL ONLY and only relates to the specifications of the minimum equipment required to
ensure safe and trouble free installation and operation, optimum performance and maximum life of the Ebsray
Pump and its related pumping system in general.
2. Products with the mandatory European CE mark affixed indicate conformity to the essential health and safety
requirements via their applicable EU Directives (eg. ATEX 94/09/EC, Machinery 98/37/EC etc).
As certain specific products/equipment outlined in this Publication are CE marked (meaning the equipment has
been assessed and supplied in conformity to those Directives), STRICT ADHERENCE with ALL the
Instructions and Recommendations forms an essential part in maintaining the product/equipment’s conformity.
Failure to comply with the Instructions and Recommendations contained in this Publication may void
CE conformity.
3. This Publication does NOT depict:
a) Ancillary required equipment related to the fabrication, installation and operation of the pump e.g.
miscellaneous flanges, fittings etc.
b) Required equipment unrelated to the pump 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 Pump and pumping system in general, meet Ebsray's minimum requirements.
c) All design, fabrication and installation of the tank and sub-systems is STRICTLY in accordance with all relevant
Federal, State and Local Codes, Directives, Regulations and Standards.
5. Ebsray reserves the right to:
a) Withdraw or alter any or all of the Ebsray Specifications within this publication and any other relevant Ebsray
Documents without notification.
b) Determine the validity of Any Warranty claims for Ebsray equipment based on the proper application of Ebsray
supplied equipment by the way of adherence to the Ebsray Specifications within this Publication and any other
relevant Ebsray Documents.
Terms used in this publication requiring special attention:
1.
non-compliance with requirements under this heading could create circumstances which may lead to
serious personal injury or death or substantial property damage.
2.
Non-compliance with requirements under this heading could create circumstances which may lead to
personal injury and/or which may cause damage to the pumpset and or ancillary equipment.
3. CAUTION
Items under this heading draw attention to legal and/or statutory requirements which control the
installation and use of this type of equipment. Non-compliance with these requirements may create a
dangerous situation and/or result in damage to the pumpset and ancillary equipment.
4. NOTE
Items under this heading are to draw attention to assembly procedures, techniques and methods of
operation etc. which are important to ensure correct installation and operation of equipment and which, if
not followed, may result in damage, failure or poor performance of pumpset and ancillary equipment.

4
WARNING
WARNING
SECTION 1 – GENERAL
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
related pumping systems.
Before starting any work, this publication should
be completely read/reviewed by all persons
involved with the work. If any part of this
publication is unclear, obtain clarification before
proceeding with any work.
As LPG (Propane and Butane) is regarded as a
flammable liquid, extreme caution must be taken to
ensure total compliance with all necessary
Directives, Statutory Standards, Codes and
Regulations is fully understood and exercised in
the installation, operation and maintenance of
Ebsray RC Series pumps.
These instructions are intended to assist correct
pump installation, operation and maintenance
requirements. They are additional to, and do not
supersede or override any applicable statutory,
legal or regulatory requirements.
CAUTION
Installation and servicing of this equipment should
be performed by qualified competent personnel in
accordance with relevant Directives, Standards,
Codes, Regulations and site requirements, in
conjunction with these instructions.
When the equipment supplied utilises components
other than those manufactured by EBSRAY e.g.
electrical equipment, switches, fittings, valves, etc
reference should be made to the original
manufacturer's data before installation or servicing is
commenced.
Failure to observe these details could result in
equipment failure and void the Warranty.
The pumpset must be operated within the original
selected design parameters of pumped product,
flow, pressure, temperature, voltage and current.
Should ANY change from original specification be
contemplated, please confer with Ebsray or
appointed Representative in order to verify the
suitability of such a change.
Standard domestic packing is suitable for shipment in
covered transports. Pump ports must be adequately
sealed to exclude ingress of condensation, moisture or
foreign material. When received on site the pump must
be stored in a dry covered area.
NOTE
If Pump is not installed and commissioned
immediately, special preservative techniques will
be required. (Refer to EBSRAY or appointed
Representative).
e.g. If the pump is installed, but not
commissioned, low pressure nitrogen can be used
to purge, seal and protect pump from the effects of
condensation and atmospheric corrosion.
NEVER allow water or any corrosive product to
enter the pump (e.g. for hydrostatic testing of
pipework). Severe internal damage may result and
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 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 or damage Pumpset! Care should be
taken in moving/handling pumps/pumpsets in order to
minimise stress on the internal components.
The pump/pumpset should be lifted ensuring
compliance with the relevant lifting codes.
Severe internal pump/pumpset damage may result
if correct handling and due care is not taken.
1.5 WARRANTY
1. All EBSRAY manufactured pumps and equipment
are warranted as standard for one (1) year against
faulty workmanship and/or materials. Refer
EBSRAY appointed representative for details.
2. Ancillary equipment supplied by EBSRAY but
manufactured by others will be in accordance with
those manufacturer's written warranty conditions.
1.2 TRANSPORTATION AND STORAGE
DANGER
DANGER

5
WARNING
SECTION 2 – SYSTEM DESCRIPTION
2.1 EBSRAY RC20/RC25 LPG PUMPING SYSTEM
The RC Series Pumps are designed for installation
aboveground when connected to aboveground supply
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 P & ID Appendix A 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 2.1
SECTION 3 – INSTALLATION
CAUTION
Installation and removal of this equipment should
be performed by qualified competent personnel in
accordance with relevant Directives, Standards,
Codes, Regulations and site requirements - in
conjunction with these instructions.
NEVER loosen or attempt to disconnect fittings,
flanges, etc. while under pressure (vapour pressure
of LPG may be very high). Always ensure total
electrical isolation and depressurisation prior to
work.
3.1 PUMP & SYSTEM LOCATION/INSTALLATION
Refer to P&ID Appendix A for system arrangement and
relative positions of important components/equipment.
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 required.
It is extremely important that no piping stresses be
transferred to the pump.
2STRAINER
The pump inlet must always be protected by an
efficient strainer of adequate size to accommodate the
flow rate conditions without causing excessive inlet
resistance or cavitation.
3 PUMP INLET
a) The pump is designed for installation with an
adequately sized inlet pipe with continuous fall from
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 that the pump and its
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 pipework TOTALLY
prior to pumpset installation.
4 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.
5 BYPASS VALVE
Bypass Valve (Ebsray Model RV18-VRS or CBS)
(Refer P & ID Appendix A 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
DANGER

6
WARNING
WARNING
WARNING
a direct effect upon discharge pressure whilst constant
differential pressure is maintained).
If VRS option is used (Refer P & ID Appendix A 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.
It is preferable that flow of LPG during bypassing
should return to vapour space of tank.
SECTION 4 – OPERATION
4.1 DESCRIPTION
1 Pump
The EBSRAY RC Series pumps are designed for ultra
quiet operation under adverse operating conditions.
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 Pre-start Inspection Checklist (Appendix B)
DO NOT RUN PUMP DRY. SEVERE INTERNAL
DAMAGE TO THE PUMP MAY RESULT.
DO NOT START PUMP WITH CLOSED INLET OR
DISCHARGE VALVES. SEVERE INTERNAL
DAMAGE TO THE PUMP MAY RESULT.
4.4 STARTUP PROCEDURE
Fill in the Pump Run Log provided in Appendix C
1. Ensure all conditions described in Pre-Startup
Checklist have been met.
2. Check reading on discharge pressure gauge.
Record product vapour pressure in the
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)
6 Start Pumpset.
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.
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.
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 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
CAUTION
Prior to any system disassembly or service, verify that all requirements of Directives, Standards, Codes or
Regulations are met and that specific site requirements etc are satisfied.
Obtain the appropriate Work Permit if required.
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.
The following instructions are for complete pump disassembly (This may not be required - depending upon scope of
maintenance):
CAUTION
Replace Ball Bearings at intervals not exceeding recommended operational hours. See Para 5.5.3
5.4 DISASSEMBLY (Refer Drawing No A316001B)
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.
(Fig 5.1)
4. Insert grubscrews
into the two
extraction holes
and screw in
evenly to extract
Cartridge or Quill
Assembly. Fig. 5.1
Fig 5.2 Complete Quill Assembly
NOTE: Complete Quill Assemblies are available
from EBSRAY as a 'Spare Part' to enhance speed
and efficiency of maintenance.
5.1 PREPARATION FOR MAINTENANCE
5.2 TO REPLACE MECHANICAL SEAL ONLY
Removal Replacement
Follow steps in Para' '5.4 Disassembly' in the following
order:
2,3,5,6,4,7.
Inspect relevant components as described in Para' '5.5
Inspection' and repair or replace as required.
Follow steps in Para' '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 Para' '5.8 Reassembly'
5.3 TO REPLACE COMPLETE QUILL ASSEMBLY ONLY
Removal Replacement
Follow steps in Para' '5.4 Disassembly' in the following
order:
1,2,3,4,9.
Inspect relevant components as described in Para' '5.5
Inspection' and repair or replace as required.
Follow steps 7 to 14 in Para' '5.8 Reassembly'

8
Fastener Torque settings
M10 Fasteners ISO grade 4.6: 20NM
M12 Fasteners ISO grade 8: 85NM
DANGER
5. Remove Circlip
from end of Quill
Assembly.
(Fig 5.3)
Fig 5.3
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.
(Fig 5.4)
Fig 5.4
8. Remove Circlip and press Bearings from Shaft.
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.5.5
MINIMUM IMPELLER DIMENSIONS mm
Pump Model RC20 RC25
Minimum worn width 8.86 9.86
Minimum worn diameter 109.86 109.86
Fig 5.5
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 or at intervals not exceeding
10,000 operational hours.
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 Model No
&Serial No located on the nameplate of the pump.
2. Advise the name, Cat # and quantity required.
Refer to Drg NoA316001B (In this publication)
3. Advise complete delivery instructions,
transportation, etc.
Substitute or so-called 'equivalent' items/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. Before assembly, ensure all parts are clean and
undamaged.
2. Ensure Impeller maintains an accurate free sliding
fit on Shaft and Key. This is critical
CAUTION
At all times when handling and installing
Mechanical Seals, take care to ensure lapped
faces and seats are clean and not damaged.
3. Lubricate all O-Rings, Lip Seals and Mechanical
Seal Faces with a compatible good quality
detergent-free light oil before assembly.
5.8 REASSEMBLY
(Refer Drg No. A316001B & Drg NoA316001L)
Reassembly is a reversal of the disassembly
procedure.
Quill Assembly
1. Fit Lip Seal to Cartridge.
(note position of lip)
(Fig 5.6)
Fig. 5.6
2. a) Fit O-Ring to Seal
Seat.
b) Fit Seal Seat to
Cartridge.
(Fig 5.7)
Fig 5.7

9
c) Press Seal Seat
in with fingers.
(Ensure
complete and
square
engagement)
(Fig 5.8)
Fig 5.8
3. Fit outer O-Ring to
Cartridge.
(Fig 5.9)
4. a) Fit IE Bearing to Fig 5.9
Shaft.
(Note: this is an
interference fit)
(Note: Apply force
to inner race of
Bearing only.)
b) Lock Bearing in
position with Circlip.
(Fig 5.10)
Fig 5.10
5. Fit DE Bearing to Shaft.
(Note: this is an
interference fit)
(Note: Apply force to
inner race of Bearing
only.)
(Fig 5.11)
Fig 5.11
6. a) Fit Bearing/Shaft
Assembly into
Cartridge.
b) Fit Seal rotating
subassembly to
Cartridge/Shaft
Assembly.
(Fig 5.12)
Fig 5.12
c) Press down and lock
in position with
Circlip.
(Fig 5.13)
Fig 5.13
Final pump assembly
7. Fit Dust Seal to Body.
(Note position of lip)
(Fig 5.14)
8. Fit outer O-Ring to Fig 5.14
Cartridge if not already
fitted in step 3 of Quill
Assembly. (Fig 5.9)
9. a) Fit Quill Assembly
to Body.
b) Lock in place with 4
grubscrews. (apply
Loctite 243 or
equivalent to
grubscrews) Fig 5.15
(Fig 5.15)
10. Fit Key and Impeller.
Ensure Impeller
maintains an accurate
free sliding fit on Shaft
and Key. This is
critical
(Fig 5.16) Fig 5.16
11. Fit O-Ring to Cover and
fit Cover to Body.
Tighten bolts to required
torque as shown on
Page 8 (5.8).
(Fig 5.17)
Fig 5.17
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 5.18
(Fig 5.18)
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.
END OF SECTION 5

10
SECTION 6 – PARTS DESIGNATION & DIMENSIONS
PARTS DESIGNATION - EBSRAY MODELS: RC20 & RC25 (Refer Drawing No. A316001B)
Cat
# Description Qty
Cat
# Description Qty
1 Body 1 35 Motor Adaptor Kit 1
2 Cover 1 36 Coupling Assembly 1
3 Impeller 1 37 Coupling Guard 2
4 O-Ring – Cover 1 37A Setscrew -Coupling Guard 4
6 Bolt 4 38 Plug - Spare Port 1
7 Plug 2 39 Pressure Relief - Seal Drain 1
8 Key - Impeller 1 40* Seal Seat 1
12 Nameplate 1 41* Rotating Seal Face 1
13 'U' Drive Screw 2 42* Seal Sleeve 1
21 Shaft 1 45* Seal Spring 6
23 Ball Bearing – Inspection End 1 46* O-Ring – Shaft 1
24 Ball Bearing – Drive End 1 47* O-Ring – Seal Sleeve 1
25 Circlip - Bearing 1 48* O-Ring – Seal Seat 1
29 55 Lip Seal - Secondary Seal 1
29A 56* Mechanical Seal Assembly 1
29B
Specific items determined by motor size and
mounting arrangement
Note: (tapped holes in motor adaptor are M10) 57 Cartridge - Mechanical Seal 1
33 Dust Seal - Bearing 1 57A Grubscrew
34 Key - Pump Shaft 1 57B O-Ring - Cartridge 1
58 Circlip - Mechanical Seal 1
1
* Cat # 40 to 48 are included in the Mechanical Seal Assembly (Cat # 56)
DIMENSIONS EBSRAY MODELS RC20 & RC25

11

12

13
SECTION 7 - TROUBLE SHOOTING
Symptom Possible Problem Possible Cause Remedy
Insufficient LPG in Supply tank Fill Supply 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 Supply
Tank and/or inlet pipe
Clean blockage from Pump, Supply 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 Supply Tank Fill Supply 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 Supply Tank
High% Butane in supply tank
Increase Vapour Pressure

14
Symptom Possible Problem Possible Cause Remedy
Receiving Tank/Vehicle Tank
already full
No problem exists
Insufficient liquid in Supply Tank Fill Supply 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 liquid
Dispenser malfunctioning or not
authorised correctly
Re-authorise or check Dispenser as
required.
Insufficient LPG in Supply Tank -
Pump Inlet (Suction) Port not fully
covered with liquid
Fill Supply 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
Obstruction 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

15
Symptom Possible Problem Possible Cause Remedy
Obstruction in Pump
impeller
Dirt/debris/contaminate in Pump Clean blockage from Pump, Supply tank
and/or inlet pipe before restarting Pump
Faulty EFV on inlet,
Bypass or Discharge
line
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 supply tank -
Pump Inlet (suction) Port not fully
covered with liquid
Fill supply 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

16

17
WARNING
WARNING
WARNING
APPENDIX B
RC20 & RC25 SYSTEM PRE-STARTUP INSPECTION CHECKLIST
Date:__________________Location:________________________Pump Model No/ Serial No. _______________ ____________
Bypass Valve Model No/ Serial No:
Installation Company:___________________________________ Installer's Name: _____________________________________
Indicate Inspection Completed with a [
[[
[in the appropriate 
1. Check for leak free installation at pump and pipe connections........................................... 
2. Check for correct pipe/port orientation (check IN / OUT marking on Pump Cover)............................. 
3. Ensure voltage is correct and that all relevant electrical components and wiring are adequate for the application. ...... 
4. Ensure motor overload relay setting does not exceed FLA of motor....................................... 
DO NOT RUN PUMP IN REVERSE.
5. Direction of rotation - This MUST be established prior to pump operation (check arrow on Pump Cover) ....... 
DO NOT RUN PUMP DRY
6. Valves should be in the following positions:
(see P & I D Appendix A for locations)
Pump Inlet Valve/s ........................................................................ OPEN ............................. 
Valves to Pressure Gauges ............................................................. OPEN ............................. 
Discharge Line Valve/s .................................................................... OPEN ............................. 
Vapour/Bypass Return Line Valve/s ................................................ OPEN ............................. 
DO NOT START PUMP AGAINST CLOSED DISCHARGE VALVE OR WITH INLET VALVE THROTTLED
7. Ensure that 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:

18
APPENDIX C
EBSRAY RC20 & RC25 INSPECTION/RUN LOG
PUMP Model No/ Serial NoSITE DATE
COMMISSIONED
NUMBER OF HOSES
SERVED
INSTALLED BY COMPANY/PERSONNEL
DATE INSPECT
SYSTEM
OK
TANK
VAPOUR
PRESSURE
(kPa/bar)
PUMP
DISCHARGE
PRESSURE
(kPa/bar)
MOTOR CURRENT
(AMPS)
PRODUCT
TEMP
(°C)
BY
(NAME)
NOTES
L1 L2 L3
COMMISSIONING SECTION
START
UP
RUN LOG SECTION

19
APPENDIX D

20
NOTES