EBARA 150DSC4 Operating Instructions, Installation & Maintenance Manual Download

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Submersible Wastewater, Sewage Pump

Model DSC4, DSCa4

Operating Instructions, Installation & Maintenance Manual

Ebara Fluid Handling

Ebara International Corporation

Summary of Contents for 150DSC4

Page 1: ...Submersible Wastewater Sewage Pump Model DSC4 DSCa4 Operating Instructions Installation Maintenance Manual Ebara Fluid Handling Ebara International Corporation ...

Page 2: ...MANUAL CAREFULLY TO ENSURE CORRECT INSTALLATION OPERATION AND MAINTENANCE BE SURE TO KEEP THIS INSTRUCTION MANUAL ON HAND FOR FUTURE REFERENCE Safety Labels Four different types of safety labels are used in this manual Please study the labels carefully so that the meaning of any safety warning you encounter is immediately clear DANGER indicates a potentially hazardous situation which if not avoide...

Page 3: ...es shown in installation drawing The discharge elbow foundation must have sufficient size and strength to support the weight of the pump body submersible motor and accessories plugs the weights of the discharge pipe and to absorb vibrations and impacts resulting from operation Usually it should weigh more than seven times the pump weight 3 2 Floor Frame Fig 1 2 and 3 Install a cable lead out elbow...

Page 4: ...E HEATED WHERE IT RUNS THROUGH THE ELBOW 3 3 Discharge Elbow Installation Fig 4 WARNING WHEN LIFTING THE PUMP USE APPROPRIATE CRANE OR HOIST AND LIFT SYSTEM CHECK POSITION AND TIGHTNESS OF LIFT SYSTEM SO THAT WEIGHT OF THE PUMP IS NOT UNBALANCED FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS ACCIDENTS Install the discharge elbow level on the bottom on the pump pit and connect the guide p...

Page 5: ... it may become impossible to lift pump Discharge elbow level should be within 0 1mm 0 04in per 1m 3 3ft both in the X and Y directions shown in Fig 4 It is recommended practice that pipe installation be carried out with the discharge elbow covered to protect against entry of concrete and mortar during the work CAUTION FIX THE ANCHOR BOLTS TIGHTLY BY FOR EXAMPLE BY WELDING THEM TO THE REINFORCEMENT...

Page 6: ... Switch Installation Fig 6 Install a water level switches for use during automatic operation If a float type switch is used each pump will required a total of 3 or 4 for starting stopping low level alarm and high level alarm Above low limit level Fig 6 ...

Page 7: ...nd the cable glands and cables are in satisfactory condition 5 Insulation resistance values are within limits See 3 6 2 6 Other points that require particular attention See 3 6 3 3 6 1 Oil Supply Fig 7 8 and 9 Mech Air vent Mech Oil port Mech Air vent Mech Oil port Fig 7 Fig 8 The motor shaft is sealed with a tandem mechanical seal The seal chamber provide between the two sealing stages can be fil...

Page 8: ...ter the sealing chamber is filled to the specified level put a sheet gasket between the plug and the boss and tighten the plug Floor surface Oil funnel Turbine Oil ISOVG32 Fig 9 Use one of the following oils or equivalent Shell Turbo oil T32 Mobil Mobil DTE oil light Esso Esso Tresso 32 Exxon Teresstic 32 Gulf Harmony 32 Crest 32 Caltex Rega Oil R O 32 ...

Page 9: ...AO 46075 GC 66075 GO 66075 2 3 BC 46100 3 1 EEC 66175 5 2 BC 46120 2 4 EEC 66200 CC 46120 3 2 EEC 66215 CC 46145 EEC 66245 CC 46175 400DSC4 D1C 106050 4 5 HC 46050 HO 46050 3 2 D1C 106060 D1C 106075 HC 46060 HO 46060 500DSC4 D2C 1060100 5 5 G1C 1060120 6 2 HC 46075 HO 46075 G1C 1060145 G2C 860175 C1C 46175 4 3 G2C 860200 C1C 46200 G2C 860215 C1C 46215 G2C 860245 C1C 46245 250DSC4 EC 66100 EO 66100...

Page 10: ...anding the pump vertically and unplugging Coolant supply hole and Air vent full level check hole CAUTION THE SEAL CHAMBER MAY BE UNDER PRESSURE HOLD A RAG OVER THE PLUG TO PREVENT SPLATTER Pour the specified coolant into the coolant chamber through Coolant supply hole until the coolant flows out of Air vent full level check hole See Table 1c After the coolant chamber is filled to the specified lev...

Page 11: ...AC 46050 AO 46050 51 250DSC4C EC 66100 EO 66100 69 AC 46060 AO 46060 57 EC 66120 EO 66120 73 AC 46075 AO 46075 60 EC 66145 EO 66145 80 BC 46100 66 300DSC4C FC 66050 FO 66050 57 BC 46120 60 CC 46120 60 FC 66060 FO 66060 60 CC 46145 68 HC 46050 HO 46050 52 GC 66075 GO 66075 60 HC 46060 HO 46060 58 HC 46075 HO 46075 61 The ingredients of the coolant are to be as follows 30 Propylene glycol 70 Water C...

Page 12: ... and 11 Connect the minus terminal to G of the DC 500V Megger to the G terminal of the power cable or a motor bolt In dual power cable connect the L4 L5 and L6 phases electrically and keep them off the ground Touch the plus terminal of the Megger to L1 phase or L2 phase or L3 phase of the power cable and read the insulation resistance Touch the plus terminal of the Megger to P1 or P2 and P3 or P4 ...

Page 13: ... INSTRUCTION MANUAL P 12 PM32U Single Power Cable 50HP 175HP models P1 P2 G L3 L1 L2 Power cable Motor P3 P4 G Protective device cable Dual Power Cable 200HP 245HP models Fig 11 ...

Page 14: ...peration when water is restores to a safe level 2 Pump location relative to pump pit water inlet If the pump is installed near the pump pit water inlet it can be considerably disturbed it can be shaken and the cables whipped by vigorous inlet water resulting in damage Therefore the pump should be located as far from the water inlet as possible 3 Size of debris Entry of large or long debris can res...

Page 15: ...o the guide pipe Then lower the pump body slowly along the pump guide The pump is automatically connected to the discharge elbow If the pump cannot be slid down smoothly the guide pipe may not be vertical or the lifting method may be wrong Check these points to determine the cause for correction After the pump is installed attach the chain to the hook of the floor frame GUIDE PIPE CHAIN HOOK DISCH...

Page 16: ... ARE BENT OR PULLED EXCESSIVELY THE CABLE AND THE MOLDED SEAL MAY BE DAMAGED RESULTING IN INSULATION FAILURE ALSO CARE IS NEED TO PROTECT CABLE ENDS AGAINST WATER INTRUSION Note The cables should be cut to the necessary length If the cable is too short it can prevent lifting of the pump If the cable is too long and laid loose on the pump pit bottom it could be sucked into the pump If left coiled o...

Page 17: ...c switch or breaker respectively Connect the remaining terminal G to ground WARNING WHEN PREPARING POWER CABLE LEADS FOR CONNECTION TO CONTROL IT IS ESSENTIAL THAT THE GROUND LEAD BE LONGER THAN THE POWER LEADS THE GROUND LEAD MUST HAVE AT LEAST 2 50 MM SLACK REMAINING AFTER CONNECTION WHEN SPACE PERMITS THIS IS DONE FOR ELECTRICAL SAFETY IF THE CABLES IS MISTAKENLY PULLED OUT THE GROUND LEAD WILL...

Page 18: ...ce Cable Connection Fig 15 and Table 3 This pump have a leakage detector at the motor bottom and a thermal protector in the stator coil to protect the motor with cable connections as illustrated in Fig 15 Connect terminals P1 and P2 for the thermal detector to P1 and P2 of the same control connector Connect the remaining terminal G to ground Table 3 shows detailed specifications regarding protecti...

Page 19: ... LAW TO PREVENT ELECTRICAL ACCIDENTS CAUTION A MOTOR PROTECTIVE DEVICE SHOULD BE INSTALLED ON CONTROL PANEL TO PROTECT THE SUBMERSIBLE MOTOR AGAINST OPEN PHASE OVER CURRENT OR INCHING 4 4 Water Level Switch Cable Connection Fig 16 and 17 Figs 16 and 17 illustrate typical float switch applications for water level control Three or four float switches are required for single unit operation whereas fo...

Page 20: ...quid level shown in the technical document 4 Voltage variations The motor is designed to supply its rated output at variations of up to 10 of the rated voltage at the rated frequency 5 Voltage balance Balance among the supply phases should not exceed deviations in excess of 1 6 Frequency variations The motor is designed do supply its rated output at variations of up to 3 5 of the rated frequency a...

Page 21: ... ON With all air released from the discharge pipe fully close the sluice valve As this time if the value of shut off head H1 H2 ft where H1 ft Compound pressure gauge reading H2 ft Vertical distance from gauge to liquid surface is generally in agreement with the pump performance at hand the pump is operating normally If the pump is reversed a performance curve as denoted by dashed lines in Fig 18 ...

Page 22: ...e water as described above cannot be performed proceed as follows Lay the pump on the ground Turn switch on and off instantaneously and check visually the rotation direction through the discharge bore of the pump The rotating direction of the pump should be clockwise when viewed form above CAUTION SINCE THE STARTING TORQUE ON LARGE PUMPS CAN BE POWERFUL THE PUMP MUST BE SUPPORTED DANGER DURING CHE...

Page 23: ...uch case open the valve within 1 minute after motor start Start motor CAUTION DO NOT START THE MOTOR IF REVERSE FLOW OCCURS 2 Stopping Stop motor Note A pump of lower shut off power than rated horse power may be stopped just after the valve is closed 5 5 Cautions During Operation Pay attention to abnormal noise and vibration If air or foreign matter enters the pump or if there is a change in the o...

Page 24: ...tems at least once a month 1 Discharge pressure Check pump discharge pressure and discharge flow rate if flow meter is provided 2 Insulation resistance Operation is safe as long as insulation resistance is more than 2MΩ If higher than 2MΩ but this occurs after a sharp decline form a certain value check the cables and or overhaul is required 6 3 Annual Checks Even if there is nothing wrong with the...

Page 25: ...is all that is required for lifting the pump It is not necessary to empty the pump pit or remove any bolts 3 If the guide pipe is deposited with dirt and the pump cannot be slip up along it smoothly do not lifting using force but clear the pipe of dirt with a stick etc 6 3 2 Inspection Procedure 1 Appearance check Check the impeller cables bolts and nuts external surface conditions for abnormal co...

Page 26: ...d tighten the plug Fig 20 3 Mechanical Seal lower a Unplug the oil drain and air vent and drain all internal oil Refer to Changing Oil Para 6 6 b If the drained oil is muddy or milky white it contains water The mechanical seal lower is in satisfactory condition as long as the oil does not contain much water Otherwise it must be replaced c After the oil has been inspected pour fresh oil Turbine Oil...

Page 27: ...he mechanical seal is a cartridge type removing the retaining ring permits seal removal as a complete assembly After the mechanical seal has been replaced with a new one reassemble the pump and supply the specified oil through the oil port in the manner describe above At this point turn the rotating body by hand to ensure that it turns smoothly Also check for oil leaks ...

Page 28: ...r is in satisfactory condition c If a very small quantity of any liquid leaks out there is no practical problem If any liquid in excess of 1 liter after one year of use leaks out the mechanical seal must be replaced d If much liquid is emitted the mechanical seal or others components may be damaged and an overhaul is necessary e When inspection is completed put a sheet gasket between the plug and ...

Page 29: ...lant 30 Propylene glycol 70 Water through the Coolant supply hole shown in Figs 7c and 8c with the pump in a vertical position till the coolant overflows from Air vent full level check hole shown in Figs 7c and 8c The quantity of coolant is shown in Table 1c d Replug Coolant supply hole as carefully as the other ports e To replace either upper or lower mechanical seal the pump must be disassembled...

Page 30: ... apparent problems 1 Cable disposition When the pump is lifted for overhaul it is necessary to disconnect all cables from the control panel terminal board At this time if the cables are pulled out from the floor level elbow reinstallation becomes difficult To prevent this pull the cables with their ends tied with string When the cables are put back into their original position after overhaul tie t...

Page 31: ...SSENBLY BE SURE TO USE APPROPRIATE CRANE OR HOIST AND WIRE ROPES USE OF IMPROPER CRANE AND WIRE ROPES CAN RESULT IN SERIOUS ACCIDENTS FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS ACCIDENTS 6 5 2 Cautions for Disassembly 1 Cautions for unloading products a When hoisting heavy loads such as the pump proper pay careful attention to attaching the sling so that the load will be centered and...

Page 32: ... parts and store parts in cases 7 Store bolts in bags as a set 8 Do not disassembly the motor If the motor requires disassembly please contact us 6 6 Replacing Components 1 Changing oil Stand the pump in a vertical position and unplug oil drain and air vent Drain all oil from the oil drain In case of model F G D1 D2 G1 and G2 using the oil pump Fig 22 Inspect the oil for water contamination If the...

Page 33: ...7c and 8c Drain all the coolant from Coolant drain hole Fig 22c Inspect the coolant for contamination If the coolant contains much pumped liquid the mechanical seal must be replaced After the coolant has been inspected pour coolant 30 Propylene glycol 70 Water through Coolant supply hole until the coolant overflows from Air vent full level check hole and tighten the plugs Refer to ICS opt Para 3 6...

Page 34: ...eal replacement Refer to Fig 24 a Remove the snap ring A from intermediate casing b Remove the mechanical seal by using push bolts B For assembly reverse the above steps After installing the mechanical seal fill the threads C with the silicon rubber sealant SHIN ETSU CHEMICAL Co Ltd KE 45 or equivalent CAUTION DO NOT COMPLETELY DISASSEMBLE THE MECHANICAL SEAL Fig 24 Special pull out tool Left hand...

Page 35: ... flange part of each assy For assembly reverse the above steps After installing the mechanical seal fill the above female threads for push bolts with the silicon rubber sealant SHIN ETSU CHEMICAL Co Ltd KE 45 or equivalent CAUTION DO NOT COMPLETELY DISASSEMBLE THE MECHANICAL SEAL Fig 24c 6 Key 5 Upper stationary side assy 4 Inner casing 3 Upper rotating side assy 2 Side plate 1 Lower stationary si...

Page 36: ...ows The standard direction should be matched with the discharge direction Fig 25c INTERMEDIATE CASING SIDE PLATE One hollow showing the standard direction of the assembly One hollow showing the Standard direction of the assembly Changing the direction by 180 degrees has no problem INNER CASING Discharge direction ...

Page 37: ... INSTRUCTION MANUAL P 36 PM32U The situation after the completion of the assembly of the mechanical seal is as follows Fig 26c ...

Page 38: ...d M8 1 1 8 0 8 6 M10 2 2 16 1 5 11 M12 3 8 28 2 6 18 M16 9 1 66 6 2 45 M20 17 8 129 12 1 88 M22 24 0 174 16 2 117 M24 30 8 223 20 9 151 M30 61 4 444 41 6 301 M36 107 0 774 72 4 524 WARNING WHEN MACHINES SURFACES ARE DAMAGED AND MUST BE REPAIRED USE AN APPROPRIATE GRINDER DURING GRINDING WORK APPROVED PROTECTIVE GOGGLES MUST ALSO BE WORN ...

Page 39: ...gh o Clogged discharge pipe Pressure too high o Clogged pump or strainer Pressure too low o Air accumulation in pipe o Internal pump wear o Wrong direction rotation o Liquid viscosity different from design value o Damaged impeller o Raise water level in pump pit o Recheck requirements o Clean discharge pipe o Clean strainer impeller and bowl o Install air vent valve o Repair and or replace o Check...

Page 40: ...or supplier for more information about other Ebara products Ebara Fluid Handling 1651 Cedar Line Drive rock Hill SC 29730 803 327 5005 t 803 327 5097 f www pumpsebara com 2015 Ebara International Corporation EICDSC4x 0415 ...

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