Toyo DP150B Manual

TYPE DP-150B to 160BHEAVY DUTY SUBMERSIBLE PUMPS

INSTALLATION,OPERATION &MAINTENANCEINSTRUCTIONS

TOYO PUMPS NORTH AMERICA CORPORATION2853 Douglas Road Telephone: (604) 298-1213Burnaby, British Columbia Fax: (604) 298-7773CANADA V5C 6H2 Parts Fax: (604) 298-1224

Email: [email protected]

Published April, 2003

TABLE OF CONTENTS

SECTION I INTRODUCTION ............................................................1I-A GENERAL ............................................................1I-B SAFETY ..............................................................1

SECTION II INSTALLATION ..............................................................2II-A CHECK UPON ARRIVAL ...........................................2II-B STORAGE ............................................................2II-C HANDLING ...........................................................2II-D PRESTARTING CHECKS...........................................2II-E MOISTURE DETECTOR INSTALLATION .........................3

SECTION III OPERATION ................................................................... 4III-A STARTING A SUBMERSIBLE PUMP .............................4

SECTION IV MAINTENANCE................................................................ 5IV-A ELECTRICAL ........................................................5IV-B OIL RESERVOIR.....................................................5IV-C BEARING LUBRICATION...........................................5IV-D MOISTURE SENSOR................................................5IV-E MAINTAINED CAPACITY..........................................5

SECTION V DISASSEMBLING AND ASSEMBLING PROCEDURES..................... 6V-A DISASSEMBLY OF LEAD INLET SECTION ......................6V-B DISASSEMBLY OF PUMP SECTION .............................6V-C DISASSEMBLY OF SHAFT SEALED SECTION..................6V-D DISASSEMBLY OF MOTOR SECTION............................7V-E INSPECTION AND PARTS REPLACEMENT GUIDELINES .....7V-F SUBMERSIBLE PUMP REASSEMBLY...........................8

SECTION VI RECOMMENDED SPARE PARTS............................................ 9§ GENERAL PERFORMANCE CURVES§ ELECTRICAL INFORMATION§ DIMENSIONAL DRAWING§ GENERAL SEAL AND LOWER BEARING ARRANGEMENT§ TYPICAL CROSS SECTIONAL DRAWING§ EXPLODED VIEW AND PARTS LIST

§ DP150B (DRAWING # A5658-A5660)§ DP160B (DRAWING # A5661-A5663)

§ MOISTURE SENSOR RELAY & ELECTRODE ARRANGEMENT

TOYO PUMPS NORTH AMERICA CORPORATION1

SECTION I -INTRODUCTION

I-A. GENERAL

Do not install this equipment other than inaccordance with the instructions contained in thismanual.

The descriptions and instructions in this manualcover the standard design of the equipment andthe more popular options when possible. Thismanual does not cover all design details andvariations, nor does it provide for everycontingency which may be encountered. Wheninformation cannot be found in this manual,contact the nearest Toyo branch office.

This instruction book should be read completelybefore starting installation, operation, ormaintenance. The equipment is capable oftrouble-free operation when properly installed,operated, and maintained. These instructionspresent the basic information and methodsrequired for proper installation and maintenance.

This pump has been designed to provide safe andreliable service; however, it is both a pressurevessel and a piece of rotating machinery.Therefore, the operator(s) must exercise goodjudgement and proper safety practices to avoiddamage to the equipment and surroundings toprevent personal injury. The instructions in thismanual are intended for personnel with a generaltraining in operation and maintenance ofcentrifugal pumps.

I-B. SAFETY

It is assumed that your safety department hasestablished a safety program based upon athorough analysis of industrial hazards. Beforeinstalling, operating or performing maintenanceon the pump and associated components describedin this manual, it is suggested that the safetyprogram be reviewed to ensure that it covers thehazards arising from high speed rotatingmachinery.

In general, all personnel should be guided by allthe basic rules of safety associated with theequipment and the process.

It should be understood that the informationcontained in this manual does not relieveoperating and maintenance personnel of theresponsibility of exercising normal goodjudgment in operation and care of the pump andits components.

Toyo Pumps reserves the right to change thedesign, construction, or material of any partwithout incurring the obligation of installing suchchanges on pumps already delivered.


SECTION I I -INSTALLATION

II-A. CHECK UPON ARRIVAL

The unit should be inspected immediately uponarrival, and any irregularities arising due toshipment should be reported to the carrier.

Care should be taken when unpacking pumps. Acopy of this instruction book as well as instructionsheets for other various components may beincluded in the shipment. Put these papers in asafe, accessible place for ready reference whenrequired. It is important that the entire contents ofthis booklet be studied before installation.

Pump parts and accessories may be packed insideshipping container, or attached to skids inindividual packages. Inspect all container, crates,and skids before discarding.

II-B. STORAGE

The pump is protected against corrosion for theperiod of shipment and installation only.

If the pump is not to be installed at once, find aclean, dry location for storage. Unit should bestored in an approximately level position with nostrains applied. Protective coverings should beleft in place. The pump can be left in its shippingcontainer or skid for storage.

The pump's grease-lubricated bearings are shippedwith grease installed, therefore, no specialpreservation measures are required. The oilchamber is shipped full and does not requirefilling before storage.

II-C. HANDLING

Use care when moving pumps. Rough handling ofthe pump can cause breakage.

Make sure that any equipment used to lift thepump or any of its components is capable ofsupporting the weights encountered. Make surethat all parts are properly rigged before attemptingto lift.

II-D. PRESTARTING CHECKS

1. Power Supply: Check and confirm that thepower supply voltage and frequency are the sameas stated on the pump name plate.

2. Grounding: Connect the pump's greenelectrical lead to ground.

3. Pump Rotation: Correct rotation iscounterclockwise as viewed from the suctionintake. Check that pump rotation corresponds tothe rotation specified on name plate.In case of incorrect rotation, switch two of thethree power leads in the cabtyre cable.

Rotation in air over extended periods can causedamage to the pump's oil seals.

WARNINGReverse rotation of the pump will causethe cutter fan to unscrew and maydamage the impeller.

4. Protection of Electric Motor: Werecommend the use of magnetic breakers to protectagainst over current.

If decreased starting torque is desired, start thepump in air and then lower the pump slowly afterit reaches its rated speed. Note that this sometimescauses an air lock which can be rectified bylowering the pump deep enough into the water.


Submersible pumps should not be operated influids above 40oC (104oF) without special Class-H motor winding or a water jacket for motorcooling.

If the pump must be operated with the motorsection in air, make sure that the motortemperature does not rise above 60oC (140oF). Ifthe temperature rises over this level either runwater over the motor or submerge the motorsection periodically.

WARNINGOverheating the motor will definitelydecrease motor life.

5. Cabtyre Cable: If additional cabtyre cableis required, please consult the factory.

WARNINGIf incorrect size cable is used or cabledistance is excessive, voltage may bereduced and motor damage couldoccur.

Never use the cable as a rope or locate it where itmay get damaged by heavy equipment.

II-E. MOISTURE DETECTORINSTALLATION

A moisture sensor is standard in this DPsubmersible agitator pump. When connected tothe relay box it provides a warning signal in theevent that water enters the oil chamber.

The moisture detector supplied with the pump is asolid state relay control with a Toyo electrodemounted within the oil chamber housing. This is avery high sensitivity relay capable of detectingsmall amounts of water as an emulsion in the oil.

We recommend that the relay be hooked up tosome kind of alarm or light (not supplied), ratherthan directly to the motor starter. This is becauseshutdown of the pump during heavy operationwill plug the pipeline. Upon tripping of the alarm,maintenance should be scheduled within 1 or 2days to replace the lower seals, shaft sleeve B andpossibly the lower bearing. The soonermaintenance is performed, the fewer parts will berequired.

Toyo uses a single cable arrangement. The cableconsists of 3 conductors for power (red, black andwhite), 1 conductor for ground (green) and 2conductors for the moisture sensor (beige “MI”and beige “E”).

The moisture sensor lead (small beige wire marked“MI”) is attached to relay input number 8 and theground (small beige wire marked “E”) is attachedto relay input number 5. The normally openportion of the load relay should be powered usinginputs 2 and 7 for 115V V.A.C. The encloseddrawing #B5683 for direct operation describes theelectrical connections required.


SECTION I I I - OPERATION

III-A. STARTING ASUBMERSIBLE PUMP

Start the pump in air briefly to check rotation(counterclockwise when viewed from the agitatorend.)

WARNING Extended operation in air may burn out the motor.

Start the pump in clear fluid to prime dischargehoses, etc. Ensure that no hoses are kinked as thepump will not force them open to start flow.Where flexible hose is required, we recommendthe use of non-collapsible hose.

Lower the pump into the pumping material slowly.

Slurry density can be observed by watching anammeter for current loading. Higher current meanshigher specific gravity and thus higher density.

Pumping density can be controlled by raising andlowering the pump into the material.

It is very important to ensure that adequate fluidvelocity in the discharge pipe is maintainedduring high density operation or settling ofmaterial in the pipe may cause blockage.

CautionNever stop the pump while pumping slurrythrough the lines. This will plug the lines andthe pump may become buried and have tobe dug out.

Ensure that the motor casing is submerged duringoperation to prevent motor damage due tooverheating.

Prior to pump shutdown, lift the pump into clearfluid for several minutes to completely flush thesystem of any slurry.

TOYO PUMPS NORTH AMERICA COPRORATION5

SECTION IV -MAINTENANCE

IV-A. ELECTRICAL

1. Check periodically that the voltage is kept atthe rated level and that voltage is balancedbetween the phases. See Table 3 for motor specs.

2. Measure the insulation resistance of the motormonthly. If the resistance value becomes less than20 Mega ohms, check moisture content of statorand motor sealing.

IV-B. OIL RESERVOIR

1. Check lubrication oil level in oil reservoir atleast every 500 hours. To fill, set pumphorizontally, remove the oil inlet cover and fill tocapacity.

2. If water (cloudy condition) and sludge havecontaminated the oil reservoir, check and replacethe shaft seals.

3. If pump is run intermittently, the oil reservoirshould be examined more often.

4. If the pump has not been operated for a longperiod of time, the oil reservoir should beexamined shortly after startup to ensure there hasbeen no deterioration of seals.

5. Use SAE #30W non-detergent or turbine oilfor oil lubrication of the pump. Oil capacity: 7.93US gallon.

IV-C. BEARING LUBRICATION

Every 1000 hours apply EP2 grease to the motorbearings. Carefully inspect the packing beforereplacing the grease inlet covers.

IV-D. MOISTURE SENSOR

If moisture sensor is tripped, go through normalshutdown procedure then immediately check andreplace the shaft seals as necessary.

IV-E. MAINTAINED CAPACITY

The amount of liquid being pumped will lessen aswear occurs between the faces of the impeller andthe impeller disc. To maintain full pump capacity,the impeller clearance must be adjustedperiodically. Each application is different and it isnecessary to determine the amount of wear for acertain time limit before setting up a schedule foradjustment.

1. Loosen the impeller disc set nuts.

2. Turn impeller clearance adjusting bolts tomove the suction cover up until it touches theimpeller. Turn the bolts in the opposite directionto lower the suction cover 0.04" (1 mm) whichgives the recommended operating clearance.

3. Tighten the set nuts to 100 ft/lb.


SECTION V - D ISASSEMBLING AND ASSEMBLINGPROCEDURES

Use a location that is dry and dust free. Prepareseveral small boxes for disassembled small parts,plus rags, chain block or crane, solvent and tools.

NOTE: For your pump model, please use theapplicable exploded view and part lists found at theback of this manual.

V-A. DISASSEMBLY OF LEADINLET SECTION

1. Remove (10) cap nuts and take off the (9A)lead cover.

2. To detach the (1) power leads of the cabtyrecable from the motor lead wire, take off the vinyltape and the insulation tape and remove theconnecting screw with a screwdriver.

3. The (1) cabtyre cable is fixed with the epoxyresin inside the (9A) lead cover. Remove it bydrilling holes into the epoxy resin and thenbreaking it with a screwdriver, etc.

4. Remove the (103) packing housing byremoving the (104) cap nuts.

5. Remove the (8) and (112) rubber packing, the(7) packing set ring, the (2) cable protection tubeand packing housing from the (1) cabtyre cable.

6. Remove the (96) set screw and take off the (97)set plate and the (98) packing from the motor leadwires.

.

V-B. DISASSEMBLY OF PUMPSECTION

1. The (92) cutter fan is threaded on the shaft,therefore remove it by hitting it counterclockwise asviewed from the strainer end. Use caution whenhitting the vanes as they are hard and brittle.

2. Remove the (88) set bolts and take off the (89)strainer.

3. Remove the (93) cap nuts and take off the (86)suction cover with the (85) impeller disc.

4. Remove the (84) connective and the (83)impeller nut by using a wrench and pull the (82)impeller from the shaft.

5. Remove the (102) key.

6. Remove the (69) cap nuts and take off the(72A) casing. Be careful not to damage thethreaded section of the bolts.

V-C. DISASSEMBLY OFSHAFT SEALED SECTION

1. Remove the (64) set bolt and take off the (63)oil inlet cover, then pour out the oil.

2. Remove the (50B) set screw and take off the(50A) collar, the (101) distance collar, the (48)distance sleeve and the (47) o-ring.

3. Remove the (68) set bolts and take off the (77)oil seal housing B with the (46) shaft sleeve.

4. Remove the (66) set bolts and remove the (60)oil chamber cover with the (45) bearing lock plateB.


V-F. SUBMERSIBLE PUMPREASSEMBLY

In general, reassembly is a reversal of thedisassembly procedures, however, take note of thefollowing items.

1. BearingsShrinkage fit - the maximum oil or inductionheating temperature should be 120oC.

2. Oil Seal and Rareflon Seal InstallationPack lip seals with grease. Insert seals into thehousing with a jig to apply even force. Do notapply unbalanced force or hammer the seals. If theseals are deformed they will be destroyed.

Install the shaft sleeve onto the shaft. Apply acoating of grease onto the sleeve, then slide theseal housing with seals onto the shaft sleeve.

WARNING Do not insert the shaft sleeve onto the

shaft after the seal housing is alreadyinstalled. This will immediately destroythe seals.

Check for seal leakage by applying pressure (about40 psi) to the oil inlet hole to confirm zero pressureloss over 1 minute.

3. Epoxy ResinIf the electrical cable sealing inside the lead coverhas been damaged, remove the sealing compoundand replace it with epoxy. Hardening time is 24hours at 25oC (77oF) or at least 4 hours at 60oC(140oF).

4. Oil ReservoirLay the pump horizontally and fill the oil reservoirto capacity (7.93 US GPM).

5. Impeller ClearanceAdjust the clearance between the impeller and theimpeller disc to 0.040" (1 mm) with the adjust andset bolts in the suction cover.


SECTION VI - RECOMMENDED SPARE PARTS

To insure against possible long and costlydowntime periods, especially on critical services,it is advisable to have spare parts on hand. A listof spare parts is found in the parts list. Repairorder will be handled with a minimum of delay ifthe following directions are followed:

1. Give model number and serial number. Thesecan be obtained from the nameplate on the pump.

2. Write plainly the name and part number ofeach part required. These names and numbersshould agree with those on the sectionaldrawings.

3. Give the number of parts required.

4. Give complete shipping instructions.

Some parts have long life and therefore do nothave to be carried in stock. These items should bechecked at regular intervals, and whenreplacement is indicated, the parts should beordered.

HEAVY DUTY SUBMERSIBLE AGITATOR PUMPS

TYPE DP-150B TO 160B ELECTRICALINFORMATION

Table 3

PumpModel

Output(HP)

Volts(V)

FullLoad(A)

BreakerSettings(A)

Eff(%)

PowerFactor

DirectStartingCurrent(A)

StartingTime(sec)

Speed(RPM)

DP150B 150 460575

176145

238196

93.592.0

0.8400.825

792960

1.3 750

DP-160B 160 460575

192159

239197

93.092.0

0.8400.825

11781428

0.98 710

Documents

Toyo DP150B Manual