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Repair and Maintenance fIELD Training for DP/DPF Pumps

Pump Cut-Away Special protection from water ingress

Standard – with 1.35 Service Factor

Rugged motor housing

Thermal sensor in motor windings Progressively Stacked Slurry Lip Seals Standard on DPF15 thru DPF150B Models

Heavy-Duty Mechanical Seal Standard on DP3 thru DP10 Models Optional on DPF15 thru DPF75 models

First response moisture sensor Standard on DPF15 thru DPF150 Optional on DP3 thru DP10 Models

Front (adjustable) and Back High Chrome Wear Plates

Toyo’s Unique High Chrome Agitator

Pump Bearings

What we will be covering today on your DP/DPF pumps: • How to set impeller clearance • Potting Cables • Megging Cables • Installation: Slurry Lip Seals • Troubleshooting Tips • Lubrication

Setting Impeller Clearance Remove Agitator & Suction Strainer Adjust the clearance between the front wear plate (impeller disc) and the impeller to .040” - .060” (1.0 - 1.5 mm)

Set Nut Adj. Bolt

To adjust the impeller, loosen the set nuts and move the impeller disc towards the impeller using the adjustment bolts. Move the impeller disc until it just touches the impeller (the impeller can still be rotated by hand with a slight drag). Be careful not to over tighten this as you can damage the impeller disc. Turn the bolts in the opposite direction ¾ of a turn to lower the suction plate approximately 1mm (0.040”). Then tighten the impeller disc set nuts.

Potting Cables Part #

Description

Mix Ratio

119182

Elan Cast Black E805 Resin

4 parts

117864

Elan Cast C3341 Hardener

1 part

VIDEOS Wire Preparation Set Ring Packing Cable Placement Wire Separation Megger Test

Remove the resin by drilling holes in the resin to weaken it and then break it with a screwdriver or chisel.

Megging Cables The following procedure is how to perform the megger check insulation resistance of the motor and cable. 1. Disconnect the power cable from the power source 2. Verify continuity between the cable ground and the motor frame 3. Test the motor and cable assembly. Using the 500 VDC Megger Tester, check the electrical insulation resistance between the cable ground conductor (green) and each power conductor in turn. 4. Any reading less than 1 meg-ohms indicates damage to the power cable and/or the motor. 5. If the reading is less than 1 meg-ohm, disconnect the power cable from the motor and megger test the insulation resistance of the motor itself in the same manner as above. 6. If all motor readings are more than 10 meg-ohms, this indicates a problem in the cable and requires immediate replacement of the cable. 7. Any motor reading less than 10 meg-ohms indicates damage to the motor in which case the motor must be checked by a qualified motor shop.

Progressive Lip Seal Installation

Shaft Sleeves Rareflon Lip Seals Nitrile Lip Seal

Troubleshooting There is a whole section in the manual on trouble shooting, here are a few key points: Pump won’t start - The motor is burned out or is burning out - The cable has been incorrectly wired to the starter.

Pump requires excessive power -

Specific gravity of the liquid is higher than the design SG. Total system head lower than pump design resulting in too much flow. Impeller clearance too tight Insufficient submergence of the motor (motor running hot).

Low flow rate or insufficient head -

Impeller is excessively worn and needs to be replaced our adjusted The discharge pipe or suction strainer is partially clogged. The discharge hose is kinked The motor direction is reversed

Troubleshooting continued… Excessive noise and vibration – – – – –

The bearings are worn or damaged and needs to be replaced Operating near shut-off (very low flow rate) Insufficient or incorrect grease in the bearings Impeller loose or damaged causing imbalance Impeller vanes clogged

Lip seals have short life – –

Shaft sleeve worn or badly scored Incorrect type of lip seals

Lubrication LUBRICANT CHECK Check lubrication oil level in oil reservoir at least every 500 operating hours or monthly. 1. 2.

Set the pump horizontally on appropriate wooden blocks with one of the oil covers facing up. Remove the oil cover and angle the pump allowing some oil to drain slightly to check the consistency. CAUTION: Be aware of the pump’s weight and its center of gravity when moving to prevent serious accidents or damage. If the oil is milky white or has water mixed in with it, replace the oil (See next slide for details)

3.

Inspect the seal on the oil cover and replace if damaged.

4.

Check oil within a few days to confirm oil is still clear. If the oil is cloudy, the pump may require disassembly for replacement of the shaft seal.

DP/DPF - Lubrication Table

Pump Model:

DP 3-2 DP 5-2

DP 7.5-2, DP 7.5B-2, DP 10-2 DP 10H-2

DPF 15 DPF 20 DPF 20B

DPF 30 DPF 30B

DPF 50 DPF 50B DPF 75 DPF 75B

DPF 100B

PROGRESSIVE LIP SEALS:

Not Applicable

Not Applicable

4.1 Liters (1.1 US Gal)

5.9 Liters (1.56 US Gal)

6.2 Liters (1.6 US Gal)

25 Liters (6.6 US Gal)

MECHANICAL SEAL:

2.2 Liters (0.58 US Gal)

2.6 Liters (0.69 US Gal)

3.3 Liters (0.87 US Gal)

4.7 Liters (1.24 US Gal)

5.0 Liters (1.3 US Gal)

25 Liters (6.6 US Gal)

Oil Replacement 1. Set the pump horizontally on appropriate wooden blocks with one of the oil covers facing up. Remove both oil covers and drain oil. Note: Used oil should be appropriately disposed of by waste disposal contractors in compliance with local regulations. 2. If water (milky white oil) and sludge have contaminated the oil reservoir, check the shaft seals and lower bearing and replace as necessary. 3. Replace the seals on the oil covers 4. Re-install the lower oil cover 5. Re-fill the oil to the quantity in the table. (previous slide)

Oil Replacement 5. Use the following oils: Pumps with lip seals ISO Grade #100 turbine oil (or non-detergent SAE 30 if turbine oil unavailable) Pumps with mechanical seals ISO Grade #32 turbine oil (or non-detergent SAE 10 if turbine oil unavailable) 6. If pump is run intermittently, the oil reservoir should be examined more often. 7. If the pump has not been operated for a long period of time, the oil reservoir should be examined shortly after startup to ensure there has been no deterioration of seals.

Check the Pump Rotation!!

Bump start the pump. Check the direction of rotation is counterclockwise when viewed from the suction end