EBARA DMLU Manual

Instruction and Operation Manual

Model DMLU

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Safety Information and Introduction

DMLU

Instruction, Operation, and Maintenance

Project: Model: Chk’d: Date:

Contents

Section Page

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Warnings in this manual provide information for safe use of your EBARA pump, and instructions for preventing injury to those

operating it. Please pay close attention to the instructions listed below. If there are any questions regarding these instructions,

please direct them to EBARA INTERNATIONAL CORPORATION.

1. Before lifting the pump, confirm the total weight of the unit listed in the catalog or outline drawing. Use the appropriate

hoist or crane assembly, and make sure that the load is balanced to prevent shifting during loading and off-loading.

2. Be sure to keep the pump from lying on the power and control cables, and do not use the power and control cables

to lift the pump. This can result in damage to the cables and can cause electrical shorts that can possibly lead to

fires.

3. A qualified electrician should perform all wiring and all national and local electrical codes must be observed.

4. Make sure that all equipment is properly grounded. Failure to do so can result in electric shock.

5. Disassembly and repair of the pump should only be performed by factory trained service centers. Errors made by

unqualified personnel can result in improper assembly and operation, therefore resulting in possible injury.

6. Always make sure that power switch is in OFF position and that power cable is disconnected before inspecting or

repairing the pump.

7. If pump is to be out of service for a long period of time, turn power off. If power is left on without operating pump it

can cause insulation breakdown, resulting in a possible motor short or electric shock.

8. Do not insert hands into the pump during operation.

9. Do not operate the pump unsubmerged, as overheating can occur, causing insulation breakdown and possible

electric shock.

10. If the insulation resistance is below 1M

Ω

, turn power off to unit as soon as possible, as electric shock can occur.

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DMLU

Delivery Checks

Project: Model: Chk’d: Date:

When your pump is delivered, check the following items immediately.

1. Pump and accessories

a.) Confirm that no damage has occurred during transportation.

b.) Confirm that all items have been delivered.

2. Nameplate

a.) The basic specifications of the pump are listed on the nameplate. Read the pump nameplate to confirm

that the pump you received matches the specifications that you ordered.

Fig. 1 – Pump Nameplate

Specifications

Item

Liquid handled Type

Temperature

Solids Capacity Discharge size (in.)

Solid size (in.)

Materials Impeller

Phase

Motor Voltage

Starting Method

Protector

Mechanical Seal Lubricants

Maximum water depth

Installation

Specifications

Waste water

0 - 40° C

3, 4, 6

Cast iron

Three Phase

60 Hz

230 or 460 VAC

2.2kW : Direct start

3.7 ~ 22kW : Star-Delta start

2.2kW : Auto-cut

3.7 ~ 22kW : Thermal Protector

Turbine oil ISO VG32

26 ft.

with Quick Discharge Connector or Floor mounted

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1. Before installation:

a.) Use a megger to measure the insulation resistance between the ground wire and each phase of the motor.

Keep the ground wire off the ground during measurement. The value of each reading should be more than 20

meg-ohms.

2. Installation:

a.) Using a chain or lifting cable assembly, lower the pump into the tank or wet well.

DO NOT USE THE POWER & SENSOR CABLE TO LIFT PUMP.

b.) Do not install the pump horizontally. Ensure that the pump is upright and on a secure base. Installation of pump

with Quick Discharge Connector (QDC) shall be in accordance with manual entitled “Quick Discharge Connector.”

c.) Install pump in a location within the tank that has the least amount of turbulence.

d.) Support the discharge piping to prevent vibration.

e.) Install proper ventilation so that air will not become stagnant.

f.) Do not permit the end of the discharge piping to become submerged, as it will result in backflow when the pump stops.

g.) Set control operating levels (i.e. floats) so that pump is not running for more than ten minutes with water level at

minimum operating level as indicated in below chart. Continuous operation of pump at minimum water level will

result in automatic cut-off switch in motor to be activated.

Figure 2

3. Electrical Wiring:

Note: All electrical wiring should be performed by a qualified electrician, and in accordance with all national

and local electrical codes. Incorrect wiring can result in serious injury.

Figure 3

a.) Wiring should be performed as indicated in Figure 3.

b.) Do not allow the end of the cables to become immersed in water.

c.) Make sure pump is properly grounded using the green ground wire in the power cable. Do not connect the

green wire to the power supply.

DMLU

Installation

Motor Size

(HP) 3 5 7.5 10 15 20 30

H2 (in) 219/16 2411/16 2713/16 2713/16 303/8303/8325/8

H1 (in) 11 11 119/16 119/16 1211/16 1211/16 1215/16

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DMLU

Installation

(continued)

Project: Model: Chk’d: Date:

d.) Motor protection:

• For 3HP motors, a built-in auto-cut is used and will be activated when motor becomes overheated due to

abnormal conditions such as locked rotor or single phasing. There is no external wiring for this feature.

• For 5HP to 30HP motors, a normally closed built-in thermal protector is used. When motor winding becomes

over-heated, the circuit is opened, shutting the motor down and allowing it to cool. An external sensor cable

is provided for this feature and must be connected to a thermal relay in the control panel. Failure to do so

will void the warranty. Specifications for the thermal protector are listed below:

Contact rating: AC 230V, 13A (Max)

Contact type: Break contact (normally closed)

1. After completing installation, measure the insulation resistance again, using the procedure described in the

“Installation” section.

2. Check to make sure there is an adequate amount of water in the wet well. Continuous operation of the pump in a

dry condition will cause the motor protector to be activated.

3. Check the direction of rotation by turning on pump. If the discharge volume is low or unusual sounds are heard, it is

likely that rotation has been reversed. If this happens, reverse two of the three power cable wires. (see Figure 4)

Figure 4

4. After confirming that the direction of rotation is correct, gradually open the discharge valve and allow the pump to run

in continuous operation. Check the voltage, current and discharge pressure to make sure they are within allowable limits.

5. If voltage, current and discharge pressure are acceptable, you may continue to operate the pump on a continuous

basis. Please refer to “Troubleshooting” section of the manual or contact your local EBARA distributor if one of these

items is outside of allowable limits.

6. Do not allow the motor to start more than 20 times per hour.

Operation

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DMLU

Maintenance

Project: Model: Chk’d: Date:

Note: Disassembly and repair of the pump should only be performed by factory trained service centers. Errors made

by unqualified personnel can result in improper assembly and operation, therefore resulting in possible injury.

1. Recommended daily inspections:

a.) Check the motor current and its fluctuation. If there is a great deal of fluctuation, something may be clogging the

pump.

b.) Check to make sure the pump is providing the correct amount of flow. If the discharge decreases dramatically,

something may be clogging the pump.

2. Recommended monthly inspections:

a.) Measure the insulation resistance. The value should be more than 1 meg-ohm. If the resistance falls rapidly

even with an initial reading of more than 1 meg-ohm, further inspection and possible repair may be required.

3. Recommended annual inspections:

a.) Check the oil in the seal chamber. If the oil has turned white it is an indication that water has mixed with the oil

and the mechanical seal needs to be replaced. The service life of the mechanical seal can be prolonged by

replacing the oil in the seal chamber on an annual basis. See the recommended amount of oil below in Figure 5.

Replace the oil by laying the pump on its side as illustrated in Figure 6.

Figure 5

Figure 6

4. Extended storage:

a.) Keep pump in a dry environment, out of direct sunlight.

b.) Every 30 days, check the insulation resistance and rotate the impeller by hand to prevent rotating parts from

seizing together.

Always turn the power OFF before inspecting and repair the pump. Failure to do so can result in serious injury.

Warning

Motor Size (HP) 3 5 7.5 10 15 20 30

Mechanical seal

(mm) 30 40 45

Lubricating oil (oz)

Turbine oil ISO VG32 38 58 102

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DMLU

Troubleshooting

Project: Model: Chk’d: Date:

Trouble

Motor won’t turn.

Starts, but immediately

stops.

Operates, but stops after

a while.Thermal protector

is activated.

Does not pump.

Inadequate volume.

Overcurrent

Pump vibrates;

excessive noise during

operation.

Cause

(1) Foreign matter hinders level control float from functioning

properly.

(2) Power failure.

(3) Large voltage unbalance.

(4) Significant drop in voltage

(5) There is an open phase

(6) Faulty circuit connection

(7) Blown fuse

(8) Faulty starter

(9) Defective float

(10) Malfunctioning circuit breaker

(11) Foreign matter clogging pump

(12) Motor is shorted out

(13) Motor bearings are frozen

(1) Prolonged dry operation has activated motor protector

and caused pump to stop

(2) High liquid temperature has activated motor protector

and caused pump to stop

(1) Reverse rotation

(2) Valve is closed or partially clogged.

(3) Significant drop in voltage

(4) Discharge head is too high

(5) Large piping loss

(6) Low water level during operation causes vortexing (air

suction)

(7) Leak in discharge piping

(8) Clog in discharge piping

(9) Foreign matter clogging pump

(10) Worn impeller

(1) Large discrepancy between power source and voltage

(2) Significant voltage drop

(3) There is an open phase

(4) Reverse rotation

(5) Low head; pumping too much liquid

(6) Foreign matter clogging pump

(7) Motor bearing is worn or damaged

(1) Reverse rotation

(2) Pump clogged with foreign matter

(3) Piping vibrates

Remedy

(1) Remove foreign matter

(2 - 3) Contact electric power company for remedy

(4) Check power supply

(5) Check power supply; Inspect starter and connections

(6) Correct wiring

(7) Replace with correct size fuse

(8) Replace with correct starter

(9) Repair or replace float

(10) Repair location of circuit

(11) Remove clog from pump

(12) Repair or replace

(13) Repair or replace

(1) Raise the off float level

(2) Lower liquid temperature

(1) Correct rotation

(2) Open valve

(3) Check power supply

(4) Recalculate and adjust

(5) Recalculate and adjust

(6) Raise water level or lower pump

(7) Inspect, repair

(8) Remove foreign matter

(9) Remove foreign matter

(10) Replace impeller

(1) Contact power company for remedy

(2) Contact power company for remedy

(3) Check power supply

Inspect starter & electrical connections

(4) Check rotation

(5) Adjust discharge valve to desired flow

(6) Remove clog from the pump

(7) Repair or replace

(1) Correct rotation

(2) Remove clog from pump

(3) Install support for discharge piping

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DMLU

Disassembly and Reassembly

Project: Model: Chk’d: Date:

1. Disassembly:

a.) Unscrew and remove the bolts (120-2), and lift the motor out of the pump casing. Lay it down on its side carefully.

b.) Unscrew and remove the impeller bolt (275), then pull the impeller (021) off the motor shaft.

c.) Unscrew and remove the oil plug (193) and drain oil from seal chamber.

d.) Unscrew and remove the bolts (120-1), and remove the mechanical seal cover (016) carefully. Take care as there

may be oil remaining in the seal chamber.

d.) Remove the mechanical seal carefully to keep from damaging the seal faces.

2. Reassembly:

a.) Perform the above instructions in reverse order, replacing the o-ring, seal washer and gasket.

Note 1:

After reassembly to the point of installing impeller on the shaft, turn the impeller by hand to make sure that it

rotates smoothly.

Note 2:

It is recommended to use a screw adhesive (LOCKTITE 271) on the impeller bolt (275) during reassembly.

Note 3:

After installing casing back onto pump, turn the impeller by hand through the pump suction to make sure that it

rotates smoothly without rubbing against the wear ring.

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DMLU

Sectional view

Project: Model: Chk’d: Date:

80DML62.2

PA R T

NO.

001

016

021

080

107

111

174

193

211

275

801

802

PART NAME

CASING

MECHANICAL SEAL COVER

IMPELLER

BUSHING

WEAR RING

MECHANICAL SEAL

DISCHARGE PIPE

OIL PLUG

AIRVENT VALVE

IMPELLER BOLT

ROTOR

S TATO R

MATERIAL

CAST IRON

STAINLESS

STEEL

BRONZE

—

CAST IRON

RUBBER (NBR)

BRASS

STAINLESS STEEL

—

NO. FOR

1 UNIT

1 SET

PA R T

NO.

811

814

816

817

830

849-1

849-2

876

904

907

PART NAME

SUBMERSIBLE CABLE

MOTOR FRAME

POWER SIDE BRACKET

OPPOSITE SIDE BRACKET

SHAFT

BALL BEARING

AUTO CUT

LIFTING HANGER

BEARING COVER

MATERIAL

—

CAST IRON

STAINLESS STEEL

—

STEEL

NO. FOR 1

UNIT

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DMLU

Sectional view

Project: Model: Chk’d: Date:

5 to 10 HP

80DML

100DML

150DML

PA R T

NO.

001

016

021

080

107

111

174

193

211

275

801

802

PART NAME

CASING

MECHANICAL SEAL COVER

IMPELLER

BUSHING

WEARING RING

MECHANICAL SEAL

DISCHARGE PIPE

OIL PLUG

AIRVENT VALVE

IMPELLER BOLT

ROTOR

STATOR

MATERIAL

CAST IRON

STEEL

BRONZE

—

CAST IRON

RUBBER (NBR)

BRASS

STAINLESS STEEL

—

NO. FOR

1 UNIT

1 SET

PA R T

NO.

811-1

811-2

814

816

817

830

849-1

849-2

856

904

907

PART NAME

SUBMERSIBLE CABLE (POWER)

SUBMERSIBLE CABLE (SIGNAL)

MOTOR FRAME

POWER SIDE BRACKET

OPPOSITE SIDE BRACKET

SHAFT

BALL BEARING

THERMAL PROTECTOR

LIFTING HANGER

BEARING COVER

MATERIAL

—

CAST IRON

STAINLESS STEEL

—

STEEL

NO. FOR

1 UNIT

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