TYPE DP-150B to 160B

HEAVY DUTY SUBMERSIBLE PUMPS

INSTALLATION,
OPERATION &
MAINTENANCE
INSTRUCTIONS
TOYO PUMPS NORTH AMERICA CORPORATION
2853 Douglas Road Telephone: (604) 298-1213
Burnaby, British Columbia Fax: (604) 298-7773
CANADA V5C 6H2 Parts Fax: (604) 298-1224
Email: [email protected]

Published April, 2003

 TABLE OF CONTENTS
SECTION I INTRODUCTION ............................................................ 1
I-A GENERAL ............................................................ 1
I-B SAFETY .............................................................. 1

SECTION II INSTALLATION .............................................................. 2

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

SECTION III OPERATION ................................................................... 4

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

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

SECTION V DISASSEMBLING AND ASSEMBLING PROCEDURES..................... 6

V-A DISASSEMBLY OF LEAD INLET SECTION ...................... 6
V-B DISASSEMBLY OF PUMP SECTION ............................. 6
V-C DISASSEMBLY OF SHAFT SEALED SECTION .................. 6
V-D DISASSEMBLY OF MOTOR SECTION............................ 7
V-E INSPECTION AND PARTS REPLACEMENT GUIDELINES ..... 7
V-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 CORPORATION
1

SECTION I -
INTRODUCTION

I-B. SAFETY
I-A. GENERAL It is assumed that your safety department has
established a safety program based upon a
Do not install this equipment other than in
thorough analysis of industrial hazards. Before
accordance with the instructions contained in this
installing, operating or performing maintenance
manual.
on the pump and associated components described
in this manual, it is suggested that the safety
The descriptions and instructions in this manual
program be reviewed to ensure that it covers the
cover the standard design of the equipment and
hazards arising from high speed rotating
the more popular options when possible. This
machinery.
manual does not cover all design details and
variations, nor does it provide for every
In general, all personnel should be guided by all
contingency which may be encountered. When
the basic rules of safety associated with the
information cannot be found in this manual,
equipment and the process.
contact the nearest Toyo branch office.
It should be understood that the information
This instruction book should be read completely
contained in this manual does not relieve
before starting installation, operation, or
operating and maintenance personnel of the
maintenance. The equipment is capable of
responsibility of exercising normal good
trouble-free operation when properly installed,
judgment in operation and care of the pump and
operated, and maintained. These instructions
its components.
present the basic information and methods
required for proper installation and maintenance.
Toyo Pumps reserves the right to change the
design, construction, or material of any part
This pump has been designed to provide safe and
without incurring the obligation of installing such
reliable service; however, it is both a pressure
changes on pumps already delivered.
vessel and a piece of rotating machinery.
Therefore, the operator(s) must exercise good
judgement and proper safety practices to avoid
damage to the equipment and surroundings to
prevent personal injury. The instructions in this
manual are intended for personnel with a general
training in operation and maintenance of
centrifugal pumps.
 TOYO PUMPS NORTH AMERICA CORPORATION
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SECTION II -
INSTALLATION

II-A. CHECK UPON ARRIVAL Make sure that any equipment used to lift the
pump or any of its components is capable of
The unit should be inspected immediately upon supporting the weights encountered. Make sure
arrival, and any irregularities arising due to that all parts are properly rigged before attempting
shipment should be reported to the carrier. to lift.

Care should be taken when unpacking pumps. A

copy of this instruction book as well as instruction
sheets for other various components may be II-D. PRESTARTING CHECKS
included in the shipment. Put these papers in a
safe, accessible place for ready reference when 1. Power Supply: Check and confirm that the
required. It is important that the entire contents of power supply voltage and frequency are the same
this booklet be studied before installation. as stated on the pump name plate.

Pump parts and accessories may be packed inside 2. Grounding: Connect the pump's green
shipping container, or attached to skids in electrical lead to ground.
individual packages. Inspect all container, crates,
and skids before discarding. 3. Pump Rotation: Correct rotation is
counterclockwise as viewed from the suction
intake. Check that pump rotation corresponds to
the rotation specified on name plate.
II-B. STORAGE In case of incorrect rotation, switch two of the
three power leads in the cabtyre cable.
The pump is protected against corrosion for the
period of shipment and installation only. Rotation in air over extended periods can cause
damage to the pump's oil seals.
If the pump is not to be installed at once, find a
clean, dry location for storage. Unit should be
stored in an approximately level position with no
strains applied. Protective coverings should be WARNING
left in place. The pump can be left in its shipping Reverse rotation of the pump will cause
container or skid for storage. the cutter fan to unscrew and may
damage the impeller.

The pump's grease-lubricated bearings are shipped

with grease installed, therefore, no special 4. Protection of Electric Motor: We
preservation measures are required. The oil recommend the use of magnetic breakers to protect
chamber is shipped full and does not require against over current.
filling before storage.
If decreased starting torque is desired, start the
pump in air and then lower the pump slowly after
it reaches its rated speed. Note that this sometimes
II-C. HANDLING causes an air lock which can be rectified by
lowering the pump deep enough into the water.
Use care when moving pumps. Rough handling of
the pump can cause breakage.
 TOYO PUMPS NORTH AMERICA CORPORATION
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Submersible pumps should not be operated in II-E. MOISTURE DETECTOR

fluids above 40o C (104o F) without special Class-
H motor winding or a water jacket for motor INSTALLATION
cooling.
A moisture sensor is standard in this DP
If the pump must be operated with the motor submersible agitator pump. When connected to
section in air, make sure that the motor the relay box it provides a warning signal in the
temperature does not rise above 60o C (140o F). If event that water enters the oil chamber.
the temperature rises over this level either run
water over the motor or submerge the motor The moisture detector supplied with the pump is a
section periodically. solid state relay control with a Toyo electrode
mounted within the oil chamber housing. This is a
very high sensitivity relay capable of detecting
small amounts of water as an emulsion in the oil.
WARNING
We recommend that the relay be hooked up to
Overheating the motor will definitely
some kind of alarm or light (not supplied), rather
decrease motor life.
than directly to the motor starter. This is because
shutdown of the pump during heavy operation
will plug the pipeline. Upon tripping of the alarm,
maintenance should be scheduled within 1 or 2
5. Cabtyre Cable: If additional cabtyre cable days to replace the lower seals, shaft sleeve B and
is required, please consult the factory. possibly the lower bearing. The sooner
maintenance is performed, the fewer parts will be
required.

WARNING Toyo uses a single cable arrangement. The cable

If incorrect size cable is used or cable consists of 3 conductors for power (red, black and
distance is excessive, voltage may be white), 1 conductor for ground (green) and 2
reduced and motor damage could conductors for the moisture sensor (beige “MI”
occur. and beige “E”).

The moisture sensor lead (small beige wire marked

“MI”) is attached to relay input number 8 and the
Never use the cable as a rope or locate it where it ground (small beige wire marked “E”) is attached
may get damaged by heavy equipment. to relay input number 5. The normally open
portion of the load relay should be powered using
inputs 2 and 7 for 115V V.A.C. The enclosed
drawing #B5683 for direct operation describes the
electrical connections required.
 TOYO PUMPS NORTH AMERICA CORPORATION
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SECTION III - OPERATION

III-A. STARTING A
SUBMERSIBLE PUMP It is very important to ensure that adequate fluid
velocity in the discharge pipe is maintained
Start the pump in air briefly to check rotation
during high density operation or settling of
(counterclockwise when viewed from the agitator
material in the pipe may cause blockage.
end.)

Caution
WARNING Never stop the pump while pumping slurry
Extended operation in air may burn out through the lines. This will plug the lines and
the motor. the pump may become buried and have to
be dug out.

Start the pump in clear fluid to prime discharge Ensure that the motor casing is submerged during
hoses, etc. Ensure that no hoses are kinked as the operation to prevent motor damage due to
pump will not force them open to start flow. overheating.
Where flexible hose is required, we recommend
the use of non-collapsible hose. Prior to pump shutdown, lift the pump into clear
fluid for several minutes to completely flush the
Lower the pump into the pumping material slowly. system of any slurry.

Slurry density can be observed by watching an

ammeter for current loading. Higher current means
higher specific gravity and thus higher density.

Pumping density can be controlled by raising and

lowering the pump into the material.
 TOYO PUMPS NORTH AMERICA COPRORATION
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SECTION IV -
MAINTENANCE
IV-C. BEARING LUBRICATION
IV-A. ELECTRICAL
Every 1000 hours apply EP2 grease to the motor
1. Check periodically that the voltage is kept at bearings. Carefully inspect the packing before
the rated level and that voltage is balanced replacing the grease inlet covers.
between the phases. See Table 3 for motor specs.

2. Measure the insulation resistance of the motor IV-D. MOISTURE SENSOR

monthly. If the resistance value becomes less than
20 Mega ohms, check moisture content of stator If moisture sensor is tripped, go through normal
and motor sealing. shutdown procedure then immediately check and
replace the shaft seals as necessary.

IV-B. OIL RESERVOIR

IV-E. MAINTAINED CAPACITY
1. Check lubrication oil level in oil reservoir at
least every 500 hours. To fill, set pump The amount of liquid being pumped will lessen as
horizontally, remove the oil inlet cover and fill to wear occurs between the faces of the impeller and
capacity. the impeller disc. To maintain full pump capacity,
the impeller clearance must be adjusted
2. If water (cloudy condition) and sludge have periodically. Each application is different and it is
contaminated the oil reservoir, check and replace necessary to determine the amount of wear for a
the shaft seals. certain time limit before setting up a schedule for
adjustment.
3. If pump is run intermittently, the oil reservoir
should be examined more often. 1. Loosen the impeller disc set nuts.

4. If the pump has not been operated for a long 2. Turn impeller clearance adjusting bolts to
period of time, the oil reservoir should be move the suction cover up until it touches the
examined shortly after startup to ensure there has impeller. Turn the bolts in the opposite direction
been no deterioration of seals. to lower the suction cover 0.04" (1 mm) which
gives the recommended operating clearance.
5. Use SAE #30W non-detergent or turbine oil
for oil lubrication of the pump. Oil capacity: 7.93 3. Tighten the set nuts to 100 ft/lb.
US gallon.
 TOYO PUMPS NORTH AMERICA CORPORATION
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SECTION V - DISASSEMBLING AND ASSEMBLING

PROCEDURES

Use a location that is dry and dust free. Prepare V-B. DISASSEMBLY OF PUMP
several small boxes for disassembled small parts,
plus rags, chain block or crane, solvent and tools. SECTION
NOTE: For your pump model, please use the
applicable exploded view and part lists found at the 1. The (92) cutter fan is threaded on the shaft,
back of this manual. therefore remove it by hitting it counterclockwise as
viewed from the strainer end. Use caution when
hitting the vanes as they are hard and brittle.

2. Remove the (88) set bolts and take off the (89)
V-A. DISASSEMBLY OF LEAD strainer.
INLET SECTION
3. Remove the (93) cap nuts and take off the (86)
1. Remove (10) cap nuts and take off the (9A) suction cover with the (85) impeller disc.
lead cover.
4. Remove the (84) connective and the (83)
2. To detach the (1) power leads of the cabtyre impeller nut by using a wrench and pull the (82)
cable from the motor lead wire, take off the vinyl impeller from the shaft.
tape and the insulation tape and remove the
connecting screw with a screwdriver. 5. Remove the (102) key.

3. The (1) cabtyre cable is fixed with the epoxy 6. Remove the (69) cap nuts and take off the
resin inside the (9A) lead cover. Remove it by (72A) casing. Be careful not to damage the
drilling holes into the epoxy resin and then threaded section of the bolts.
breaking it with a screwdriver, etc.

4. Remove the (103) packing housing by

removing the (104) cap nuts. V-C. DISASSEMBLY OF
5. Remove the (8) and (112) rubber packing, the SHAFT SEALED SECTION
(7) packing set ring, the (2) cable protection tube
and packing housing from the (1) cabtyre cable. 1. Remove the (64) set bolt and take off the (63)
oil inlet cover, then pour out the oil.
6. Remove the (96) set screw and take off the (97)
set plate and the (98) packing from the motor lead 2. Remove the (50B) set screw and take off the
wires. (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 plate
B.
 TOYO PUMPS NORTH AMERICA CORPORATION
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V-F. SUBMERSIBLE PUMP 3. Epoxy Resin

If the electrical cable sealing inside the lead cover
REASSEMBLY has been damaged, remove the sealing compound
and replace it with epoxy. Hardening time is 24
In general, reassembly is a reversal of the hours at 25o C (77o F) or at least 4 hours at 60o C
disassembly procedures, however, take note of the (140o F).
following items.
4. Oil Reservoir
1. Bearings Lay the pump horizontally and fill the oil reservoir
Shrinkage fit - the maximum oil or induction to capacity (7.93 US GPM).
heating temperature should be 120o C.
5. Impeller Clearance
2. Oil Seal and Rareflon Seal Installation Adjust the clearance between the impeller and the
Pack lip seals with grease. Insert seals into the impeller disc to 0.040" (1 mm) with the adjust and
housing with a jig to apply even force. Do not set bolts in the suction cover.
apply unbalanced force or hammer the seals. If the
seals are deformed they will be destroyed.

Install the shaft sleeve onto the shaft. Apply a

coating of grease onto the sleeve, then slide the
seal housing with seals onto the shaft sleeve.

WARNING
Do not insert the shaft sleeve onto the
shaft after the seal housing is already
installed. This will immediately destroy
the seals.

Check for seal leakage by applying pressure (about

40 psi) to the oil inlet hole to confirm zero pressure
loss over 1 minute.
 TOYO PUMPS NORTH AMERICA CORPORATION
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SECTION VI - RECOMMENDED SPARE PARTS

To insure against possible long and costly

downtime periods, especially on critical services,
it is advisable to have spare parts on hand. A list
of spare parts is found in the parts list. Repair
order will be handled with a minimum of delay if
the following directions are followed:

1. Give model number and serial number. These

can be obtained from the nameplate on the pump.

2. Write plainly the name and part number of

each part required. These names and numbers
should agree with those on the sectional
drawings.

3. Give the number of parts required.

4. Give complete shipping instructions.

Some parts have long life and therefore do not

have to be carried in stock. These items should be
checked at regular intervals, and when
replacement is indicated, the parts should be
ordered.
 HEAVY DUTY SUBMERSIBLE AGITATOR PUMPS
TYPE DP-150B TO 160B ELECTRICAL
INFORMATION
Table 3

Pump Output Volts Full Breaker Eff Power Direct Starting Speed
Model (HP) (V) Load Settings (%) Factor Starting Time (RPM)
(A) (A) Current (sec)
(A)

DP150B 150 460 176 238 93.5 0.840 792 1.3 750
575 145 196 92.0 0.825 960

DP-160B 160 460 192 239 93.0 0.840 1178 0.98 710
575 159 197 92.0 0.825 1428